Elastic composite, and a system and method for making the elastic composite

ABSTRACT

A method of making an elastic composite is provided. The method entails conveying a first web of material along a web plane path. The method also entails applying a first section of a first elastic strand onto the first web and generally transversely to the web plane path and applying a second section of a second elastic strand onto the first web and generally transversely to the web plane path. These applying steps are repeated while performing the conveying step, thereby arranging a plurality of first and second elastic elements on the first web, in generally parallel relation to one another. The resultant composite is suitable for incorporation into a disposable absorbent garment, textile or fabric structure, and the like.

The present application claims the benefit of the filing date of U.S.Utility application Ser. No. 11/021,424, filed on Dec. 23, 2004 (nowpending), which application claims the benefit of ProvisionalApplication Ser. No. 60/532,480, filed on Dec. 24, 2003. The aboveapplications are hereby incorporated by reference for all purposes andmade a part of the present disclosure.

BACKGROUND OF THE INVENTION

The present invention relates generally to elastic composites. Moreparticularly, the present invention relates to an elastic composite thatcan be employed in one or more areas of a garment, other textile orfabric structures, similar material structures, and the like. Thepresent invention also relates to a system and method of making theelastic composite and a garment, other textile or fabric structures, andthe like, employing the elastic component. The elastic composite and thesystem and method for making the elastic composite are particularlysuited for use with or on disposable absorbent garments or articles suchas baby diapers and training pants. To illustrate the invention,exemplary and preferred embodiments described in the context ofdisposable absorbent garments.

Disposable absorbent garments contemplated by the invention includedisposable diapers, disposable pull-on garments, and the like. Thesegarments are worn about the lower torso or waist of the user so as toreceive and contain urine and other bodily wastes. The benefits providedby the use of a disposable diaper on an infant are well known and itsuse has become widespread in the past several decades. Disposablepull-on garments include training pants, pull-on diapers, disposableunderwear, and adult incontinence garments. It is generally expectedthat the user of any one of these garments will be able to put on andtake off the garment on his/her own. As for training pants, thesegarments are used by young children to facilitate the child's transitionfrom using diapers to wearing regular underpants (i.e., during toilettraining). Training pants (and other disposable pull-on pants) haveclosed sides such that the user or caregiver raises the garment aboutthe user's legs to put it on and slips the garment downward about theuser's legs to take it off.

The principal elements of a typical disposable absorbent garment includea liquid permeable inner layer (or topsheet), a liquid impermeable outerlayer (or backsheet), and an absorbent core sandwiched between the innerand outer layers. Elastic members may be incorporated into differentparts of the garment. For example, elastic members may be positionedlongitudinally along a diaper, generally outboard of the absorbent coreto effect a seal around the buttocks, legs, or both of the users. Inaddition, several elastic members (e.g., in the form of elongatedelastic threads or strands) may be positioned laterally throughout thewaist regions (including the side waist regions) of a disposableabsorbent garment. The resulting elastication allows the garment tostretch when it is put on and then during wear. In this way, the garmentcan stretch to accommodate variations in waist size and leg size of theuser, while fitting snugly about the waist and legs.

When elastic members are incorporated into a part or area of thegarment, that part or area typically becomes a distinct, functionalcomponent of the garment. These elastic components include the sidepanels or ear portions, the waistband, and fastening tabs. The elasticcomponents to which the present invention is directed is generallyelongated, and may be a distinct portion of a larger, unitary piece, ora separate, attachable component. Furthermore, the elastic componenttypically contains one or more sections or layers in addition to theelastic members. In this regard, such an elastic component may bereferred to as an elastic composite.

These elastic composites are typically functional components that havean important impact on the fit and sealability of the garment. Due inpart to its multi-component construction, these elastic compositestypically require a dedicated sub-process for manufacture which must beaccommodated by the larger garment manufacturing process. Alternatively,the elastic composite may be manufactured independently and fed into thelarger process as a complete product. The design and construction of theelastic composite represents, therefore, a significant portion of thecost of manufacturing a disposable absorbent garment, as well as thequality and utility of the finished product.

It is, therefore, desirable to provide a functionally and/or anaesthetically improved elastic composite and an improved method ofmaking the elastic composite and also system therefor.

SUMMARY OF THE INVENTION

For purposes of the present description, the term “elastic band” or“elastic composite” refers to a multi-layer construction. In thisconstruction, a plurality of elastic members, such as threads orstrands, are disposed adjacent one or more layers, e.g., backsheet andtopsheet. In this way, the elastic members impart elasticity to theadjacent layers and thus, to that part of the garment or other textilestructure. Such an elastic structure may be a distinct attachablecomponent of the garment or textile structure or may be a distinctportion or section of the garment body or textile structure or a larger,unitary component of the garment body or textile structure.

In one aspect of the present invention, a method of making an elasticcomposite is provided. The method entails conveying a first web ofmaterial along a web plane path. The method also entails applying afirst section of a first elastic strand onto the first web and generallytransversely to the web plane path and applying a second section of asecond elastic strand onto the first web and generally transversely tothe web plane path. These applying steps are repeated while performingthe conveying step, thereby arranging a plurality of first and secondelastic elements on the first web, in generally parallel relation to oneanother. The resultant elastic composite is suitable for incorporationinto a disposable absorbent garment and the like.

In another aspect of the invention, a system is provided for making anelastic composite for incorporation into a disposable absorbent garmentand the like. The system includes a source of a first web of material, aweb conveyor assembly including a first web moving platform for movingthe first web thereon along a first web plane path, and a spinning headassembly. The spinning head assembly is provided for applying a sectionof a first continuous elastic strand and a section of a secondcontinuous elastic strand about the web conveyor assembly and a firstweb being moved thereon. The spinning head assembly is positioned suchthat a first web being conveyed on the platform is movable into the pathof each of the two sections of elastic strand being spun by the spinninghead assembly to apply the two sections thereon.

In another aspect of the present invention, a method of making anelastic composite is provided. The elastic composite is provided forincorporation into a disposable absorbent garment, textile, or fabricstructure and the like. The method entails conveying a first web ofmaterial in a web plane moving direction and conveying a second web ofmaterial in the web plane moving direction. The method further entailsapplying a section of a continuous strand of elastic element generallylinearly onto both the first web and the second web along a directiongenerally transverse to the web plane moving direction. The applyingstep may be repeated a plurality of times, thereby arranging a pluralityof sections of first and second elastic elements on each of the firstweb and the second web, in generally parallel relation to one another.

In another aspect of the invention, a system is provided for making anelastic composite for incorporation into a disposable absorbent garment,textile, or fabric structure, and the like. The system includes a webconveyor assembly including a first web moving platform for moving afirst web thereon and a second web moving platform for moving a secondweb thereon. A spinning head assembly is also provided for applying asection of a first continuous elastic strand about the web platforms anda first web and a second web being moved therealong. The spinning headassembly is positioned about the first and second web moving platformsto spin the section of elastic about a plane intersecting the first andsecond webs moving therealong. The first and second web moving platformsare spaced laterally apart such that the first and second webs aregenerally coplanar about sections whereupon the intersections betweenthe plane and the first and second webs are located.

In one aspect of the invention, an elastic composite is provided in adisposable absorbent garment such as a diaper or training pants. Theelastic composite has a base layer, a top layer, and an elasticconstruction disposed therebetween. The elastic construction includes aplurality of spaced apart (e.g. preferably generally equally spacedapart) elastic elements (e.g. strands or threads) that are aligned ingenerally parallel relation. Further, the top and base layers define afirst side edge, a second side edge, and a longitudinal centerlinetherebetween. The elastic construction is disposed between the twolayers and extends in a direction that is between the side edges and isgenerally parallel with or corresponds to (i.e., overlays) thelongitudinal centerline. Further, the elastic elements are orientedalong a lateral direction that intersects the side edges andlongitudinal centerline (e.g., such that each elastic element isoriented or aligned along a direction that is generally perpendicular tothe side edges).

Preferably, the elastic composite includes at least one elasticizedregion, wherein the elastic construction is disposed, that is spacedinwardly from the side edges and, in some embodiments, positionedgenerally centrally between the side edges. Such an elastic compositealso includes a first non-elasticized region disposed between the firstside edge and the elasticized region, and a second non-elasticizedregion disposed between the second side edge and the elasticized region.

In certain embodiments, the first and second non-elasticized regionsprovide fastening regions that are generally flat relative to theelastic regions, and may be equipped with a fastening element such asadhesives or a hook or loop element. More preferably, the elasticelements are attached to at least one of the top and base layers suchthat the elasticized region is shirred when the elastic composite isdisposed in a relaxed, un-stretched state. In further embodiments, asecond elasticized region is provided between the side edges and a thirdnon-elasticized region is provided between the first and secondelasticized regions.

In preferred embodiments, the elastic construction has a centerlineextending therethrough that is spaced generally equidistantly from eachside edge and the elastic strands are distributed along this centerlineand in generally perpendicular relation therewith. Preferably, thedirection of this centerline corresponds with a machine direction of theelastic composite band or more specifically, the web material from whichthe elastic composite band is cut.

In yet another aspect of the invention, a disposable absorbent garmentis provided with a topsheet, a backsheet, and an absorbent core disposedbetween the topsheet and the backsheet and such that a longitudinalcenterline of the garment extends through the topsheet, backsheet, andabsorbent core. Together, the topsheet, backsheet, and absorbent coreprovide a central body of the disposable absorbent garment. Theinventive garment further includes an elastic composite band that isattached to the central body. The elastic composite band has a firstside edge, a second side edge, and a composite centerline extending inbetween the side edges. The elastic composite band includes a baselayer, a top layer, and an elastic construction disposed between the topand base layers and spaced inwardly from each side edge. The elasticconstruction includes a plurality of spaced apart elastic elements thatare distributed in a direction extending between the side edges and eachaligned in generally perpendicular relation with the compositecenterline.

Preferably, the elastic composite band includes an elasticized regionthat is positioned generally centrally between the first and second sideedges, and wherein the elasticized region is disposed. The elasticcomposite also has a first non-elasticized region positioned between thefirst side edge and the elasticized region, and a second non-elasticizedregion positioned between the second side edge and the elasticizedregion. In some embodiments, the elastic composite band is attachedadjacent an end of the garment leg (e.g., along a waistline) andprovides therealong an elastic waistband on the garment. In furtherembodiments, the garment has two elastic composite bands each attachedalong a side margin of the garment. In these embodiments, the elasticcomposite band provides an elastic waist fastening portion of thediaper, such as an elastic side panel or ear portion of the garment orelastic fastening tab. In one particular embodiment, the elasticcomposite is provided as the central chassis or central body of thegarment.

The present invention also relates to a system and a method for makingthe elastic composite and/or the garment incorporating the elasticcomposite.

In one aspect of the present invention, a method is provided for makingan elastic composite. The elastic composite is made for incorporationinto a disposable absorbent garment. The method includes the step ofproviding an elastic element applicator configured to move a section ofa continuous strand of elastic element generally about a plane. A firstweb of material (e.g., non-woven material) is conveyed in a web movingdirection such that the first web intersects the plane. Then, theelastic element applicator is operated to move the elastic element aboutthe plane, thereby applying the section of elastic element onto thefirst web along a direction generally transverse to the web movingdirection. Preferably, the elastic element is applied such that thesection of elastic element is retained by the first web and the firstweb draws the continuous elastic strand from the elastic elementapplicator as the first web is conveyed away from the plane. Morepreferably, the elastic element applicator is a spin cylinder orbracket, that is operated to spin the elastic element about the movingfirst web, thereby applying the elastic element on the first web.

In another aspect of the present invention, another method is providedfor making an elastic composite for incorporation into a disposableabsorbent garment. The method includes the step of conveying a first webof material and folding each of the side edges of the first web along aside fold line and inwardly toward an inward surface of the first web.This creates a pair of folded flaps adjacent the inward surface and anexposed outward surface having a width defined between the fold lines(i.e., at the folded side edges). A plurality of spaced apart elasticstrands is subsequently applied across the width of the exposed outwardsurface. Then, the applied elastic strands are cut proximate each of thefold lines of the first web (i.e., along the folded side edges), suchthat the lengths of the elastic strands are generally equal to the widthof the outward surface. Thereafter, the folded flaps of the first webare unfolded such that the resulting first web has, applied thereon, aplurality of centrally located elastic strands and non-elasticized sideregions defined generally outward of the fold lines. Preferably, theelastic strands are applied in spaced apart, generally parallelrelation. Furthermore, the elastic strands are preferably applied byspinning a continuous elastic strand about the first web.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a plan view of a disposable absorbent garment in the unfoldedconfiguration; according to the present invention;

FIG. 2A is a plan view of an elastic composite according to the presentinvention;

FIG. 2B is a plan view of the elastic composite of FIG. 2A shown in anextended, stretchable condition;

FIG. 3 is a perspective view of the elastic composite of FIG. 2A with acut-out detail to show an elastic construction;

FIG. 4 is a plan view of an alternative disposable absorbent garmentaccording to the invention;

FIG. 4A is a plan view of a convertible or converted disposableabsorbent garment according to the invention;

FIG. 5 is a plan view of another alternative disposable absorbentgarment, according to the invention, incorporating an elastic compositeas a waistband;

FIG. 6 is a plan view of yet another alternative disposable absorbentgarment, according to the invention, further incorporating an elasticcomposite as a central body chassis;

FIG. 6A is a plan view of a convertible or converted disposableabsorbent garment according to the invention;

FIG. 7 is a plan view of an alternative elastic composite according tothe present invention;

FIG. 8 is a perspective view of yet another alternative elasticcomposite according to the invention;

FIG. 8A is a perspective view of yet another alternative elasticcomposite according to the invention;

FIGS. 9A-9C are plan view of a further alternative disposable absorbentgarments, according to the invention;

FIG. 10 is a simplified schematic of a system for manufacturing theelastic composite according to the present invention;

FIG. 11 is a top view of an elastic element applicator assembly for usewith the system of FIG. 10;

FIG. 12 is a side view of the assembly of FIG. 11;

FIG. 13 is a simplified process illustration of making the elasticcomposite according to the invention;

FIG. 14 is a detail view of a conveyor assembly for the system of FIG. 1according to the invention;

FIG. 15 is a top view of an alternative elastic element applicatorassembly for use with the system of FIG. 10, according to the invention;

FIG. 16 is a simplified illustration of a folding guide assembly for usewith the system and method according to the invention;

FIG. 17A is a perspective view of an elastic composite used forreference;

FIG. 17B is a perspective view of an elastic composite, according to oneembodiment of the present invention;

FIG. 18A is a perspective view of another elastic composite used forreference;

FIG. 18B is a perspective view of an alternative elastic composite,according to another embodiment of the present invention;

FIG. 19A is a top view of a system for making an elastic composite,according to an embodiment of the present invention;

FIG. 19B is a side view of the system in FIG. 19A;

FIG. 20A is a top view of a system for making an elastic composite,according to an alternative embodiment of the invention;

FIG. 20B is a side view of the system in FIG. 20A;

FIG. 21A is a cross-sectional view through line AA in FIG. 19B;

FIG. 21B is a cross-sectional view through line BB in FIG. 19B;

FIG. 21C is a cross-sectional view through line CC in FIG. 19B;

FIG. 21D is a cross-sectional view through a web output of elasticcomposite, according to the present invention;

FIG. 22 is a simplified flow chart illustrating basics steps of a methodof making an elastic composite, according to the present invention;

FIG. 23 is a top view of a system for making an elastic composite,according to an embodiment of the present invention;

FIG. 24 is a perspective view of the system in FIG. 23;

FIG. 25A is a cross-sectional view through line AA in FIG. 23;

FIG. 25B is a cross-sectional view through line BB in FIG. 23;

FIG. 25C is a cross-sectional view through line CC in FIG. 23;

FIG. 26 is a cross-sectional view of a web output of elastic composite,according to the present invention;

FIG. 27 is a simplified flow chart illustrating basic steps of a methodof making an elastic composite, according to the present invention;

FIG. 28A is a perspective view of an elastic composite having dualelasticized regions;

FIG. 28B is a perspective view of another elastic composite having dualelasticized regions;

FIG. 28C is a perspective view of an elastic composite having dualelasticized regions, according to another embodiment of the presentinvention;

FIG. 29A is a simplified illustration and front view of an alternativeelastic element applicator in the form of a spinhead, according to thepresent invention;

FIG. 29B is a simplified illustration and top view of a web substrateconveyed in a method of making an alternative elastic composite,according to the present invention;

FIG. 30A is a simplified illustration and front view of an alternativeelastic element applicator in the form of a spinhead, according to thepresent invention; and

FIG. 30B is a simplified illustration and top view of a web substrateconveyed in a method of making an alternative elastic composite,according to the present invention.

DETAILED DESCRIPTION OF THE INVENTION

Each of FIGS. 1 and 4-9 depict a disposable absorbent garment embodyingvarious aspects of a first described invention. More particularly, eachof these Figures depict such a garment that incorporates an elasticcomposite structure or elastic composite in accordance with thatinvention. In FIG. 1, a disposable absorbent garment 110 is shown thatis suitable for the invention and in the form of a diaper having one ormore elastic composites incorporated therein. The elastic composite inFIGS. 1-8 have side and end edges and, thus, may be referred to hereinas elastic composite bands. FIGS. 9-16 illustrate a system and processof making the elastic composite (and a garment having the elasticcomposite) in accordance with another described invention.

FIGS. 17-20 and 29-30 are now provided to illustrate another method orprocess of making an elastic composite (and a garment having the elasticcomposite), and a system for making or manufacturing the elasticcomposite, in accordance with the present invention. These figures alsoembody various aspects of the present invention in the form a novelelastic composite, a web output of the elastic composite, and/or amaterial structure, such as a disposable absorbent garment, textile orfabric structure, similar material structures, and the like, and intowhich the elastic composite is incorporated. The described system andprocess are particularly focused on the application or integration ofthe elastic elements upon or with one of the layers of the composite.

FIGS. 21-28 are also provided to illustrate yet another method orprocess of making an elastic composite (and a garment having the elasticcomposite), and a system for making or manufacturing the elasticcomposite, in accordance with an alternative embodiment of the presentinvention. These figures also embody various aspects of the presentinvention in the form a novel elastic composite, a web output of theelastic composite, and/or a material structure, such as a disposableabsorbent garment, textile or fabric structure, and the like, into whichthe elastic composite is incorporated. The described system and processare particularly focused on the application or integration of theelastic elements upon or with one of the layers of the composite.

As described previously, various aspects of the present invention areparticularly suited to or for a disposable absorbent garment, such asbaby diapers and training pants. To illustrate the invention andpreferred embodiments of the invention, much of the following DetailDescription will be provided in the context of such disposable absorbentgarments. It is contemplated that various aspects of the inventivecomposite, garment, system, and process may be applicable to othermaterial structures and processes. This Detailed Description andexemplary embodiment should not, therefore, be construed as limiting theinvention to the structures, configurations, methods, and processesdescribed herein.

The disposable absorbent garment 110 in FIG. 1 is of a type that can beplaced against or in proximity to the body of a wearer so as to absorband to contain various bodily exudates. It should be noted, however,that the present invention is applicable to a variety of disposableabsorbent articles and garments, including training pants and a varietyof adult incontinence products. As will be described below, theinventive elastic composite or elastic composite band may provide a sidepanel or ear portion, a waistband, a fastening tab or band, or otherdistinct elastic component of the garment or article. The inventiveelastic composite may also be incorporated into an ear portion toelasticate the ear portion or to supplement the ear portion with anelasticated fastening tab. Accordingly, the present invention is notintended to be limited to the structures and the processes specificallydescribed and illustrated herein. For purposes of description, however,the following discussion will be directed to an exemplary disposablediaper only. Moreover, the invention will be described in the context ofits various configurations and aspects. It should be appreciated thatalternative arrangements of the inventive disposable absorbent garmentand such an elastic composite band may comprise various combinations,which include one or more of the various configurations and aspects ofthe invention.

FIG. 1 is introduced to illustrate some basic features of a disposablediaper 110, most of which are also applicable to other disposableabsorbent garments contemplated by the invention. The diaper 110includes three main regions aligned along an imaginary longitudinal axisor plane AA. These regions include a first waist region 112 (typicallyat the front of the user when the garment 110 is worn), a back waistregion 114, and a crotch region 116. The diaper 110 is alsocharacterized by a front edge 140, a back longitudinal edge 142, a firstlateral or side edge or side margin 144, and a second lateral or sideedge or side margin 146.

Along a lateral direction, the diaper 110 includes ear regions or earportions 118 extending laterally from the waist regions 112, 114.Together, the waist regions 112, 114 and crotch region 116 may bereferred to as forming a central body portion 120 of the garment 110that is positioned within side edges 144, 146. The body portion 120 mayalso be referred to as being formed by a liquid permeable inner layer ortopsheet 152, a liquid impermeable outer layer or backsheet (not shown),and an absorbent core 154 sandwiched between the two layers. The earportions 118 further include fastening tabs 124 for attaching the waistregions 112, 114 together. The diaper 110 also has an elastic waistband130 positioned generally along the back edge 142 to facilitate fasteningand to enhance the fit and seal of the diaper 110. When the hourglassshaped diaper 110 is worn, the crotch region 116 fits about the crotchof the wearer, and the front and back waist regions, 112 and 114, fitabout the corresponding waist areas. The ear portions 118, on the otherhand, wrap about the wearer and the fastening tabs 124 engage to form acomplete, all-around waistline of the diaper 110.

FIG. 2A depicts a typical elastic composite band 210 according to theinvention. More particularly, the elastic composite band 210 is oneparticularly suited for use as a side panel or fastening tab of adisposable absorbent garment (see, e.g., FIG. 1). FIG. 3 provides aperspective view and partial cut-out of the elastic composite band 210.The elastic composite band 210 may be characterized by an imaginarycenterline LL. In one aspect of the invention, the centerline LLpreferably corresponds with the machine direction of the elasticcomposite band 210 during manufacture. The elastic band 210 also hasside or longitudinally extending side edges 210 a and 210 b andlaterally extending end edges 210 c and 210 d. In FIG. 1, the elasticcomposite band 210 is shown in the stretched state as, for example, whena garment incorporating the elastic composite band 210 is worn. In thisstate, the elastic composite band 210 stretches, in the lateral orcross-machine direction (denoted by arrows XX).

As used herein, the term “machine” direction refers to the direction atwhich the component, or more particularly, the material web from whichthe elastic composite is derived (e.g., cut from) is driven in anassembly line during manufacturing. The term “cross-directional machinedirection” or “cross-directional,” on the other hand, refers to thedirection that is perpendicular to the machine direction. With referenceto the elastic composite 20 of FIG. 2, the cross machine direction isthe direction XX extending laterally or perpendicularly relative to thelongitudinal line LL.

The elastic composite band 210, according to the invention, has acentral region 214 in which an elastic construction is situated.Extending laterally from this central elastic or elasticized region 214are regions 216 and 218, which are substantially non-elasticized. Asshown in FIG. 2A, the regions 216, 218 occupy the expanse between thecentral elastic region 214 and the side edges 210 a, 210 b. Now withreference to FIG. 3, the elastic composite band 210 has a top layer 318and a bottom or base layer 320. The two layers 318, 320 preferablyextend the total width and length of the elastic composite band 210,thereby providing the side edges 210 a, 210 b, and the end edges 210 c,210 d. Both the base layer 320 and the top layer 318 are preferably anon-woven, breathable, disposable material such as propylene, non-wovenfabric, breathable polyethylene/polypropylene films, or non-porous films(or combinations of these materials). The base layer 320 and top layer318 adhere to one another, thereby sandwiching and securing a pluralityof elastic strands 322 therebetween.

The elastic strands 322 may be substituted, in alternative embodiments,by suitable elastic elements such as elastic strands, threads, ribbons,and elastic glue beads. In one aspect of the invention, the elasticelements or strands 322 are distributed along a direction that extendbetween the side edges 210 a, 210 b and parallel with (or correspondingto) center line LL. Further, each elastic element 322 is generallyaligned or oriented in a direction corresponding with the lateral orcross-machine direction, i.e., in a direction generally perpendicular tothe longitudinal center line LL and intersecting the side edges 210 a,210 b. Preferably, the strands 322 are disposed in generally parallelrelation and spaced apart generally equally along the longitudinaldirection. More preferably, the elastic strands 322 are of generallyequal length. Accordingly, when the elastic composite band 210 is worn,the strands 322 impart elasticity into the structure which allows theband 210 to stretch in the lateral or cross-machine direction XX.

The elastic strands 322 are preferably tensioned during securementbetween the top and base layers 318, 320. FIG. 2B illustrates theelastic composite band 210 in a laterally stretched condition. In thiscondition, the central elastic region 214 has a width that is almostequal to the non-elasticized zones 216 and 218. When returned to thenon-laterally stretched or relaxed condition, as shown in FIG. 2A, thecentral elastic region 214 contracts and crimps to a substantiallyreduced width. In this condition or state, the contracted elasticstrands 322 shirrs the elastic composite 210 and provide pleats 234 inthe contracted elastic region 214.

The elastic composite band 210 may originate from a web of material thatis wound onto spools or festooned. Typically, the user of such materialwill cut the material to a length required of a particular application.In some applications, one such web of material may provide the source ofmultiple components of the inventive disposable absorbent garment.

Returning to FIG. 1, the inventive disposable absorbent garment 110employs one or more elastic composite bands according to the invention,as described above. The disposable absorbent garment 110 employs in eachof the ear portions 118, a fastening tab 124 having the inventiveelastic composite construction. As the fastening tab 124, the elasticcomposite band is configured such that one non-elasticized region 124 ais attached to and overlaps the central body 120 of the garment 110while a second non-elasticized region 124 b is situated outboard of theside margins 144, 146. An elasticized region 124 c, as shown in FIG. 1,provides elasticity, and thus, stretch in the lateral or cross-machinedirection (of the elastic composite). In respect to the rest of thegarment 110, the elasticity or stretch provided by the central elasticregion 124 c directed along a direction that is generally perpendicularto the longitudinal center line AA of the garment 110, and correspondswith a direction that wraps about the waistline of the user.

The disposable absorbent garment 110 in FIG. 1 also provides an elasticcomposite, according to the invention, as the waistband 130. Thewaistband 130 is situated centrally in the waist region 114. Further,the elastic composite waistband 130 is disposed such thatnon-elasticized regions 130 a, 130 b are positioned outwardly of thelongitudinal line AA of the garment 110, while an elasticized region 130c is positioned centrally across the longitudinal center line AA.Moreover, the elasticized region 130 c is configured such that theelastic strands are aligned or oriented in a direction that is generallyperpendicular to the longitudinal center line AA. In this way, theelastic composite waistband 130 imparts elasticity about the waistregion 114 of the garment 110, and in a direction corresponding with thedirection of waistline about the user.

FIG. 4 depicts an alternative disposable absorbent garment 410 accordingto the invention. Specifically, FIG. 4 depicts a disposable absorbentgarment 410 employing elastic composites according to the invention asattachable ear portions or side panels 414. The elastic composite sidepanels 414 are separate components that are attached to a central body420 of the garment 410. The elastic composite side panels (or earportions) 414 are attached near one waist edge 442 of the garment 410and such that the centerline AA of the side panel 414 is generallyparallel with the longitudinal centerline AA of the garment 410.Moreover, each of the elastic composite side panels 414 has anon-elasticized region 414 a that is positioned outboard of the sidemargins 446 of the garment 410 and a second non-elasticized region 414 bthat is attached inboard of the side margin 446 (or side margin 444).Thus, a central elastic region 414 c is situated outboard of the sidemargin 446 and not directly attached thereto. When the garment 410 is inuse, the central elasticized region 414 a allows the side panel tostretch in a lateral or cross-machine direction that corresponds withthe lateral direction relative to the longitudinal centerline AA of thegarment 410. Accordingly, when the garment 410 is worn, the elastic sidepanel 414 allows for stretching about the waistline of the user.

FIG. 5 depicts yet another alternative embodiment of a disposableabsorbent garment 510 according to the invention. The disposableabsorbent garment 510 is a diaper partially defined by end or waistedges 540, 542 (not shown) and side margins 544, 546. Further, theinventive disposable garment 510 has a central body 520 and a separate,attachable elastic waistband 530. Similar to the garments 110, 410 inFIGS. 1 and 4, respectively, the garment 510 employs an elasticcomposite, as the elastic waistband 530. The inventive elastic waistband530 is attached adjacent a waist edge 542 of the garment 510 and ispositioned centrally about the longitudinal centerline AA. The elasticcomposite waistband 530 is situated such that non-elasticized regions530 a, 530 c extend laterally past the side margins 544, 546,respectively. The central elasticized region 530 c is positionedcentrally within the central body 520 and side margins 544, 546. Theelastic strands of the central elastic region 530 c is further situatedsuch that the elastic region 530 c provides elasticity or stretch in alateral direction relative to longitudinal centerline AA. Again, in thisway, the elastic composite waistband 530 according to the inventionallows for the garment to fit snugly and effectively about the waistlineof the user.

FIG. 6 illustrates an alternative disposable absorbent garment 610,according to the invention (wherein like reference numerals are used toindicated like elements), in which the inventive elastic composite bandis incorporated into various areas or as various garment components. Thegarment 610 has a front waist region 112, a back waist region 114, and acrotch region 116 positioned therebetween. As with the garment 410 ofFIG. 4, an elasticized composite band 614 is attached to each sidemargin 144, 146, near end edge 140, as an elasticized side panel 614. Asecond pair of elastic composite bands is attached as an elasticizedside panel 660 along the opposite end edge 42 of the garment 610.

FIG. 6 also illustrates the use of the inventive elastic composite bandto provide an elasticized central body or chassis 680 at or beneath thecrotch region 116 of the garment 610 and in support of an absorbent core(not shown so as to clearly display the chassis 680). The absorbent coreis preferably adhered to and movable with the elasticized chassis 680.Thus, the core is preferably a conformable (changes shape in accordancewith an outside force), elastic, or extensible (e.g., pulled andpermanently stretched) body, as is generally known in the art. In thisway, the main or central body of the garment 610 is elasticized in alateral direction XX that is generally perpendicular to a longitudinalcenterline AA of the garment 610. In the garment 610 of FIG. 6, theinventive composite band provides the entire length of the central bodyor chassis 680. The elastic composite chassis 680 has an elasticizedregion 680 c situated between two non-elasticized regions 680 a, 680 b.Preferably, the elasticized region 680 c provides an elasticconstruction of a plurality of elastic strands as disclosed previouslyin respect to the embodiments of FIGS. 1-5. In the illustratedembodiment, the elasticized region 680 c extends between end edges 140,142, thereby imparting lateral elasticity (stretchability) across theentire garment length.

Now turning to FIG. 4A, the disposable absorbent garment 410′ isprovided with fastening means 460 along the margins 444, 446, and nearone end opposite of the elastic composite side panels 414. Provision ofthe fastening means 460 allows for fastening of the ends of the garment.Accordingly, this particular garment 410 is referred to as a convertibleor converted garment, in that it allows the garment to be used as adiaper and alternatively, as a training pants type garment.

The fastening means 460 may be provided with fastening elements such ashooks or loops which can correspondingly adhere or attach to thenon-elasticized zones 414 a, 414 b of the side panels 414. The garment410′ may come with the fastening means 460 attached with the side panels414, in the way of a training pant. Furthermore, the fasteners 460 maybe detached from the side panel 414, in the way of a diaper.

Now turning to FIG. 6A, the disposable absorbent garment 610′ is alsoprovided with fastening means 660 on the elastic composite side panel614. The fastening means 660 may include fastening elements such ashooks or loops, which can adhere and attach to the non-elasticized zone614 a, 614 b of corresponding side panel 614.

FIG. 7 depicts an alternative embodiment of an elastic composite bandaccording to the present invention. The elastic composite band 710illustrated therein differs from the previously described elasticcomposite band (see e.g. FIGS. 2 and 2 a) in that the elastic compositeband 710 includes two elasticized regions 714 a and 714 b. Theelasticized region 714 a, 714 b are preferably equidistantly spacedapart on either side of the longitudinal centerline AA. The spacing ofthe elasticized regions 714 a, 714 b creates right and leftnon-elasticized or dead regions 716, 718, as well as centralnon-elasticized region 750. The elasticized regions 714 a, 714 b impartselasticity to elastic composite band 710 a in the lateral directions XX,and in the central non-elasticized region 750, also in the oppositelateral direction VV.

FIG. 8 depicts yet another embodiment of an elastic composite band 810according to the invention. The inventive elastic composite band 810has, as in previously described embodiments, a central elastic orelasticized region 814 and regions 816 and 818 that are substantiallynonelasticized and extend laterally from the central elasticized region814. The elasticized region 814 is again comprised of a plurality ofelastic strands 322 that are disposed in generally parallel relation,and generally perpendicular with a longitudinal centerline LL of theelastic composite band 810 (and the elasticized region 814). The elasticcomposite band 810 also has end side edges 810 a, 810 b, and end edges810 c, 810 d.

In yet another aspect of the invention, the elastic composite band 810is further comprised of base layer 820 and top layer 824. As shown inFIG. 8, base and top layers 820, 824 sandwich the elastic strands 822therebetween. In contrast to previously described embodiments, layers820 and 824 are offset in respect to one another. Specifically, the twolayers 820, 824 are not positioned squarely or evenly one atop another,but overlap. In this way, the elastic composite band 810 is made wider.In particular, by offsetting the two layers 820, 824, the nonelasticizedregions 816, 818 are extended and may be referred to as having anoutside section (e.g., 818 a) formed by one of the layers 820, 824 andan inside section (e.g., 818 b) having both a top and a bottom layer820, 824. Preferably, the two layers 820, 824 are two plies of nonwovenmaterial. The wider nonelasticized, nonwoven regions 816, 818 provide aworking area on which fastening materials and other accessories orstructural attributes of the disposable absorbent garment may besituated. In various embodiments, the offset or overlap of the twolayers 820, 824 may be varied so as to create nonelasticized regions816, 818 of various widths. Moreover, a wider elastic composite band(and specifically, nonelasticized regions of the elastic composite band)is attained, without increasing the size of the nonwoven layers.

FIG. 8A illustrates a further variation of the elastic composite band810 in FIG. 8, in accordance with the present invention. Specifically,FIG. 8 depicts an inventive elastic composite band 810′ having a centralelastic or elasticized region 814′ and regions 816′ and 818′ that aresubstantially nonelasticized (“dead zones”) and extend laterally fromthe central elasticized region 814′. The elasticized region 814′ isagain comprises of a plurality of elastic strands 822′ that are disposedin generally parallel relation and generally perpendicular with alongitudinal centerline LL of the elastic composite band 810′ (and theelasticized region 814′).

In this particular embodiment of the invention, the elastic compositeband 810′ includes a base layer 820′ and a top layer 824′ that issignificantly narrower than the base layer 820′. The base and top layers820′ and 824′ sandwich the elastic strands 822′ therebetween.Preferably, the width of the top layer 824′ is no less than 5 mm widerthan the width of the central elasticized region 814′. This designfurther illustrates yet another aspect of the invention, and amanufacturing process, which results in a reduction of the raw materialcosts of the disposable absorbent garment, and more specifically, theelastic composite band 810′.

FIGS. 9A-9C are provided to illustrate further embodiments of thepresent invention. More specifically, FIGS. 9A-9C provide alternatedesigns, specifically alternate shapes, of the inventive elasticcomposite band. In these figures, like elements are referenced usinglike numerals.

Referring to FIGS. 9A and 9B, a disposable absorbent garment 910 isshown having a central body 920 and elastic composite bands in the formof ears or side panels 924. The ears 924 have inner and outernonelasticized regions 924 a, 924 b, and a central elasticized region924 c situated therebetween. These two figures illustrate an elasticcomposite band according to the invention having nonelasticized regions924 a and 924 b that are different from one another and do not provideside edges of the elastic composite band 924 which are in generallyparallel relation. In both designs, the side edge of the outernonelasticized regions 924 b are rounded or curved. The shape of theelastic composite bands 924 in these two figures provide, among otheradvantages, a more attractive product as perceived by the consumer.

Now turning to FIG. 9 c, yet another variation of the elastic compositeband 924 is shown applied to a training pants 910. Specifically, theinventive elastic composite band 924 has nonelasticized regions 924 aand 924 b of different geometries. This design of the elastic compositebands 924 provide an aesthetic as well as a functional advantage. Thefunctional advantage comes in the form of an improved fit around thewearer's leg, particularly due to the shape of the elastic compositeband 924.

FIGS. 10-16 depict a system and system components, and illustrate amethod or process of making or manufacturing the elastic compositeaccording to one embodiment of the invention. In one aspect of theinventive process, two elastic composite web outputs 1031 are producedfrom four separate non-woven web inputs 1003 a, 1003 b, 1003 c, and 1003d. To facilitate the description of the present invention, reference maybe made to U.S. Pat. Nos. 3,627,621 and 2,902,395, each of whichdiscloses certain features of the prior art system and process formanufacturing a lamination and/or composite having non-woven materials.Each of these patents is hereby incorporated by reference and made apart of the present disclosure. In particular, reference may be made tocertain basic components of a system or apparatus for manipulatingnon-woven materials and fibers.

Referring first to FIG. 10, a system 1001, according to the invention,includes four separate non-woven web inputs 1003 a-1003 d, which providea web or roll of non-woven material for the elastic composite. Thesystem further includes an output assembly or reel 1005 that receivestwo elastic composite webs 1031 from the rest of the process. These twoseparate elastic webs may be fixed together to produce the kind ofcomposite described in respect to FIG. 7 (or maintained separately).

Central to the inventive system 1001 are a conveyor assembly 1009 forreceiving, manipulating, and conveying each of the non-woven web inputs.The conveyor assembly 1009 is positioned and operatively associated withan elastic element applicator such as a spinning head assembly 1007,that applies elastic fibers or strands upon, onto, and or integrallywith the non-woven web inputs. The spinning head assembly 1007 furtherincludes a spin head 1017, preferably in the form of a spinning bracket,or cylinder 1017 and the like. The spin cylinder 1017 is configured tohold an “end section” of the continuous strand WW of elastic and move itabout a generally vertical plane XX in a reciprocal or repetitivepattern (relative to the conveyor assembly 1009). This plane XX isdefined by the area within the spinning perimeter of the cylinder 1017and which is traced by the outer most bracket or eye 1017 b securing thestrand of elastic WW to the spin cylinder 1017. The paths of thespinning head 1017 and the section of elastic strand retained therebyare provided on the plane XX.

As shown in the schematic of FIG. 10, nonwoven inputs 1003 a and 1003 bare fed, utilizing a series of rollers, into the conveyor assembly 1009.Before the two nonwoven webs are fed into the conveyor assembly 1009,the webs are directed through the folding guides or plates 1039. Thefolding guides 1039 serve to effectively reduce the overall width of thenonwoven web by folding the lateral or side edges along a predetermined,longitudinally-extending side fold line YY. The first folding guide 1039a initiates the first 90° turn while the second folding guide 1039 binitiates a second 90° turn. The roller 1039 disposed in between theguide 1039 a, 1039 b facilitates the folding process. The two foldingguides 1039 and roller 1369 may be referred together as a folding guideassembly.

FIG. 16 illustrates yet another typical folding guide assembly. Thefolding assembly 1639 includes folding plates 1639 and a roller 1669upstream of the folding plates 1639. A web 1603 is passed around thenarrow roller 1669, whereby the width of roller 1669 helps determine thewidth of the web 1603 between the folded flaps VV (i.e., the width ofexposed outward surface 1689 defined between the fold lines YY). Thewidth of the roller 1669 is substantially less than the width of thenonwoven web 1603. As a result, the edges of the nonwoven web 1603 listand curl up around the sides of the roller 1669, thereby initiating thefolding process. The flat plates 1639 then helps to complete the foldand hold the folded sides down. Another folding guide (not shown) may beprovided in a position upstream of the folding roller 1669 to help guideor initiate the folding process.

For purposed of the present Description, the inward surface 1679 is thesurface or side of the web 1603 toward which the folded flaps VV areturned. The exposed outward surface 1689 is the surface opposite of theinward surface 1679.

The conveyor assembly 1009 is set up so as to guide these two nonwovenwebs 1003 a and 1003 b through the center of the assembly 1009 towardsand eventually inside the elastic spin cylinder 1007 (into the spinningpath). Once inside the spin cylinder 1017 the conveyor assembly 1009delivers the nonwoven webs to each outside, upper and lower faces(outward faces) of the conveyor assembly 1009. At this point thedirection of travel of the nonwoven webs are reversed and the webs aredirected out of the spin cylinder 1007. As the nonwoven webs exit thespin cylinder 1017, an elastic strand WW is wrapped around the entireconveyor assembly 1009, and as it contacts the upper and lower face ofthe web platforms it comes into contact with the nonwoven web. As shownin several of the Figures, the elastic strand WW is applied crosswise orlaterally on the web, and transverse to the direction of the moving web.The friction between the tensioned elastic strand and the nonwoven webson the upper and lower faces of the conveyor assembly draws the“wrapped” elastic strand out of the spin cylinder 1017 and towardscontact with two further nonwoven webs 1003 c and 1003 d.

The nonwoven webs 1003 c and 1003 d are operatively positioned upstreamof an adhesive applicator 1013. Utilizing a system of rollers inconjunction therewith, the non-woven inputs 1003 c, 1003 d and adhesiveapplicators 1013 apply a web of pre-glued non-woven material onto theconveyor assembly 1009 and onto the elastic strand “wrapped” around thenonwoven webs 1003 a and 1003 b.

Furthermore, the system 1001 employs a standard elastic input source,e.g., a bobbin of elastic yarn, that feeds elastic strands or fibers WWonto a tensioning/speed controlling unit 1037 and then to the spincylinder or the spinning head 1017, so as to apply the strands WW ontothe conveyor assembly 1009 and the non-woven material webs conveyedtherethrough. Elastic is taken off the bobbin, box or positive drivesystem and fed through a tension and speed controlling motor towards thespin cylinder 1017. The elastic WW is delivered through a hollow shaftin the motor controlling the spin cylinder 1017. The elastic WW thenpasses into the spin cylinder 1017 and is guided by rollers, eyes or anyother suitable mechanism around the inside face of the spin cylinder1017.

In alternative embodiments of the invention, the above components may bepositioned differently in respect to one another, and may employ otherstandard components not discussed herein. Moreover, the system andprocess illustrated may be readily integrated into or with one ofseveral known systems and processes for manufacturing disposableabsorbent articles and garments. Such integration will be apparent toone skilled in the relevant consumer product or other relevant art, uponreading and viewing the present disclosure.

FIGS. 11 and 12 provide alternate views of the spinning head assembly1007 and conveyor assembly 1009. As discussed above, the conveyorassembly 1009 receives four separate webs of non-woven materials andoutputs two webs 1031 of elastic composite. FIGS. 13 and 14 are providedto further illustrate the process of making the elastic compositeaccording to the invention. These figures, more particularly FIG. 13,illustrates the paths taken by the non-woven web materials to and fromthe conveyor assembly 1009.

Referring to FIG. 13, reference letters A-G are used to refer to stagesin the process and in conjunction with the description of the process.As discussed above, non-woven raw material webs are fed into the processat stage A. These webs provide four separate non-woven web inputs intothe process. Non-woven webs 1 and 3 are combined to make an elasticcomposite output 1 (i.e., referred to in the Figures as the WRAPoutput). Non-wovens 2 and 4, which are both on the downside of thespinning head assembly 1007 and conveyor assembly 1009, combine to makea second elastic composite output 2 (i.e., WRAP 2).

At stage B, non-woven webs 1 and 2 are folded prior to being directed tothe conveyor assembly 1009. A predetermined width of non-woven is foldedover each side of the web to make two folded flaps VV. The width of theflap VV determines the width of the dead zone or non-elasticized regiondescribed previously, while the width of the non-woven, after folding,determines the width of the elasticized region. At stage C, thenon-woven webs 1 and 2 are fed into the conveyor assembly 1009, inparticular into the middle or inside of the conveyor assembly 1009 withthe folded side of each web facing the outside of or away from theconveyor assembly 1009. It should be noted that at this stage C,non-woven webs 1 and 2 are not bonded together. The conveyor 1009 thenfeeds the non-woven webs 1 and 2 towards the spinning head assembly1007. At stage D, the non-woven webs 1 and 2 have traveled almost thelength of the conveyor assembly 1009 and progresses into the spinningpath of spinning head assembly 1007 and intersecting the “spinning”vertical plane XX of the elastic strand WW. Further, at the end of theconveyor assembly 1009, the webs 1 and 2 are directed away from eachother and onto the outside of the conveyor 1009 and away from thespinning head 1007. Non-woven web 1 turns up on the upper side of theconveyor assembly 1009, while non-woven web 2 travels along the lowerside of the conveyor assembly 1009. At stage E, an elastic strand WW iswound around the folded non-woven webs 1 and 2, as these webs passthrough the spinning head and the vertical plane XX. The elastic strandWW is applied to the moving webs 1 and 2 cross-directionally to thedirection of the moving web. The movements of the webs 1 and 2 away fromwithin the spin cylinder 1017 draws the “wrapped” elastic strand out ofthe spin cylinder 1017.

Now turning to non-woven webs 3 and 4, these webs are provided to theconveyor assembly 1009 with adhesive applied on one side (i.e., appliedby the adhesive applicator 1013). At stage F, the non-woven webs 3 and 4are brought into contact with webs 1 and 2, respectively, and theelastic strands WW. As a result, the webs 1 and 3 sandwich elasticstrands WW on the upper side of the conveyor assembly 1009, andnon-woven webs 2 and 4 sandwich elastic strands WW on the under side ofthe conveyor assembly 1009. The elastic strands WW run between the twonon-woven elastic non-woven composite (cross-direction), but is then cutby a knife (see knife 1410 in FIG. 14, as described below), therebyseparating the two wrapped composites. At stage G, the composites 1 and2 are fed away from the conveyor assembly 1009 and the folded flaps onwebs 1 and 2 become unfolded, with guiding, to form a flat non-wovencomposite. Subsequently, the composites are guided from the spinninghead assembly 1007 and conveyor assembly 1009 and into furtherprocesses. As shown in FIG. 10, the elastic output webs arrives via asystem of rollers onto an elastic composite output reel 1005.

FIG. 14 provides an alternate view of the conveyor assembly 1009. ThisFigure further illustrates the movement of non-woven webs 1-4, and theapplication of elastic strands in a generally mutually parallel patternand generally spaced apart from one another. After cutting of theelastic with the knife 1410, two elastic composites are directed awayfrom the conveyor assembly 1009. It should also be noted that theinventive system advantageously allows for improved control of thestretch of the elastic strands.

As shown in FIGS. 11 and 14, the conveyor assembly 1009 preferablyincludes two web moving platforms 1412 which are juxtapositioned so asto provide an interface therebetween. Each web moving platform 1412includes a continuous belt 1414 supported about a plurality of rollers1416 so as to be capable of reciprocal motion. The two web movingplatforms 1412 are generally the same length and juxtapositioned so asto accommodate the non-woven webs 1 and 2 therealong from one end to theother end. Preferably, a roller 1416 is situated about midway betweenthe ends of the web moving platform so as to deliver the non-woven webs3and 4 respectively to the web moving platform.

As shown in FIG. 10 and also FIG. 14, the spinning head assembly 1007 ispositioned about and in the vicinity of one end of the conveyor assembly1009. In operation, the spinning head 1017 spins about the verticalplane XX which intersects the ends of the web moving platforms 1412 soas to deliver the elastic strands WW around and about both web movingplatforms 1412. In operation, the first and second non-woven move alongthe outside or exposed surfaces or sides of the web moving platforms1412 and receives the elastic strands WW delivered by the spinning head1017. By way of its movement away from the spinning head 1017, themoving web draws the continuous elastic strand WW from the spinning head1017.

By pre-folding the two non-woven webs that are fed to the inside of theconveyor assembly 1009, it is possible to create an elastic compositewith cross directional stretch having non-elasticized regions (“deadzones”) along each edge. The width of the central elasticized region isfixed to the width of the conveyor platform 1412. The width of thenon-elasticized regions or dead zones is determined by the width of thefold VV. The fold VV in the non-woven is preserved by the conveyorassembly 1009 during application of the elastic element and is appliedin such a way that the folded edge of the non-woven is not in contactwith the elastic element WW. The fold VV is then allowed to open afterthe composite exits the conveyor assembly 1009 to provide a flat elasticcomposite with non-elasticized regions. By altering the alignment of thematerials as it enters the conveyor assembly 1009 or by changing thewidths of the materials used it is possible to create various compositedesigns.

The above-described process provides an elastic composite with crossdirectional stretch properties. The process also providesnon-elasticized regions on either latitudinal side of the centralelasticized zone of the composite. For the purposes of the descriptionthe term “non-woven” is used to describe the principal material used inthe construction of the elastic composite. However, it should be notedthat this invention is not limited to non-woven materials but may beapplied to any material that is available in the form of a continuoussheet. Other materials suitable for this application include PE film, PEfilm/non-woven laminates and tissue.

FIG. 15 illustrates a conveyor assembly 1509 and an elastic elementapplicator in the form of a spinning head assembly 1507, in accordancewith an alternative embodiment of the present invention. As will beunderstood by one skilled in the art, the spinning head assembly 1507 isoperated to convey or transmit elastic strands onto a web movingplatform 1512 of the conveyor assembly 1509. As before, the conveyorassembly 1509 preferably employs two web moving platforms 1512, whichare juxtapositioned so as to provide an interface therebetween. Theconveyor assembly 1509 is similar to that illustrated in FIGS. 10 and11.

On the other hand, the conveyor assembly 1509 is operated differently inthat more than one elastic strand WW is applied onto and about the webmoving platforms 1512 at one time. The spinning head assembly 1507includes a spinning head in the form of a spin bracket 1517 having aplurality of arms 1517 a. The spin bracket 1517 receives elastic strands1553 from a shaft 1551 a of a motor 1551. The motor 1551 feeds the twolines of elastic strands 1553 to the spin bracket 1517, and the twofeeds of elastic strands 1553 are guided together through the spinninghead assembly 1517 (where the two lines twist together). As shown inFIG. 15, the two strands 1533 are moved about a v vertical plane thendelivered, together, onto a nonwoven web 1544 moving horizontally on theweb moving platform 1512. Preferably, both lines of elastic strand 1553are fed onto the same arm 1517 a of the spinning bracket assembly 1517(rather than on opposite sides). In this way, the separate feeds orlines of elastic strands 1553 are prevented from twisting together andpossibly breaking.

By applying two lines (or more) of elastic strands onto the movingnonwoven web, the speed of the manufacturing process is increased.Specifically, the speed at which the composite is manufactured may beincreased by up to 100%, without increasing the speed at which thespinning head assembly is spinning and without changing the overallnumber of elastic strands in the final composite. Table 1 below providestwo examples of the result of a process of applying the elastic strandsWW onto a nonwoven web, according to the present invention. The spinninghead assembly 1517 operates at the same rotational speed in bothprocesses. However, the pitch (i.e., the separation between elasticstrands WW) is doubled for the alternative process (wherein a pair ofelastic strands are applied to the nonwoven web). By employing thealternative process, the total machine output is also doubled (i.e.,from 40 m/min of composite to 80 m/min). In both examples, the overallamount or length of elastic strands WW utilized or applied to thecomposite is generally the same. Consequently, the final compositeproduced by both subprocesses have the same, or at least, similartensile characteristics. TABLE 1 No of elastic Spin head Pitch (elasticstrands fed Total machine output speed separation) into spin head (twowebs of composite) 8,000 rpm 2.5 mm 1 40 m/min 8,000 rpm 5 mm 2 80 m/min

It will be apparent to one skilled in the relevant art, upon reading thepresent description and/or reviewing the accompanying drawings, that thealternative subprocess described above may be modified to feed or applya different number of elastic strands onto the nonwoven web. That is,three or more elastic strands may be fed through the spinning headassembly and applied to the nonwoven web.

Moreover, it is contemplated that the elastic strands may be separatedinside the spin head and directed independently to opposite sides of thenonwoven web. In such a case, it is preferred that the assembly 1507that includes the elastic bobbins/reel and tensioners and guides theelastic strands into the motor 1551 (or more appropriately, the motorshaft 1551 a), is rotated at the same speed and in the same direction asthe spin head 1517. In this way, the risk of twisting of the strandstogether inside the spin head 1517 is minimized.

FIGS. 17A-19B are provided to illustrate aspects and embodiments ofanother present invention. In particular, FIGS. 17B and 18B depictalternative elastic composites according to the invention. FIGS. 19A and19B illustrate an exemplary system that is operable to implement amethod of making the elastic composite also according to the invention.The exemplary system may be used with or integrated into the system(s)previously described in respect, for example, to FIGS. 10-16. Theinvention, and its various aspects and embodiments, shall be understoodin view of FIGS. 17A-19B and/or the accompanying descriptions, as wellas the previous illustrations in FIGS. 1-16 and accompanyingdescriptions.

These additional Figures are provided for illustration and to facilitatea description the present invention. The present invention shall not,therefore, be limited to the structures and processes specificallydescribed and illustrated in respect to FIGS. 17A-19B. FIGS. 1-16, andaccompanying descriptions, demonstrate application of a tensionedelastic strand across a moving web of nonwoven sheet. The elastic strandwas affixed to the nonwoven sheet so as to provide a composite having,among other attributes, cross-directional elasticity. In respect toprevious illustrations, the elastic strand, or a group of elasticstrands, were fed via a single path and then applied to a moving web ofnonwoven sheet by operation of a spin head. The elastic strand or groupof elastic strands are distributed onto the web at the rate of onestrand per single revolution of spinhead.

In a further aspect of the invention, a method is now described wherebymultiple strands, e.g., two strands or two separate group of strands,are applied to a moving web of nonwoven sheet. Preferably, the strandsor collection of strands travel by two separate paths and aredistributed onto the web of nonwoven sheet at the rate of two strandsper single revolution of the spinhead. The two strands may be appliedsimultaneously to different portions of a conveyor assembly conveyingone or more webs. This variation of the invention provides advantages inefficiency as the output of the machine is increased by at least 100%.Alternatively, the machine speed may be reduced by as much as 50%,providing a reduction in running costs due to wear and tear and energyconsumption. The present inventive method maintains, however, the sameoutput and volume as the single path processes previously described.

The following terms are used to describe certain system(s) andprocess(es) for making an elastic composite. In particular, these termsdescribe different running configurations associated with thisalternative method of manufacturing an elastic composite. First, theterm “single strand, single path method (SSSP)” refers to a method ofmanufacture whereby one strand of elastic element is delivered to a webof nonwoven sheet at the rate of one strand per single revolution of thespinhead and via a single path or mode of travel through the spinhead.This method was previously described in respect, for example, to FIG.13. Second, the term “multiple strands, single path method (MSSP)”refers to a method of manufacture whereby multiple strands of elasticelement are grouped together and distributed via a single path or modeof travel through the spinhead. In this method, the elastic strands aredistributed on the web of nonwoven sheet at the rate of one collectionof strands per revolution of the spinhead. An example of this method wasdescribed in respect to FIG. 15.

Furthermore, the term “single strand, dual path method (SSDP)” refers toa method of manufacture whereby two strands of elastic element entersthe spinhead and are distributed onto the web of nonwoven sheet via twoseparate paths or modes of travel, in accordance with the presentinvention. In this method, the elastic elements are distributed on themoving web of nonwoven sheet at the rate of two strands per revolutionof the spinhead. The term “multiple strands, dual path method (MSDP)”refers to a method of manufacture whereby two sets of more than onestrand are collectively grouped and are distributed on the web via twoseparate paths or modes of travel through the spinhead. In this method,the elastic elements are distributed at the rate of two collections ofstrands per revolution of the spinhead.

As used hereafter, a substantially long feed of elastic may be referredto as a “continuous strand” even though it is understood that the strandis not infinitely long. Relative to the dimensions of the elasticelements arranged on the elastic composite, the elastic strand is, forpractical purposes, continuous. For present purposes, the term“continuous”, as applied to “strand”, shall indicate a length that willnot be consumed in less than a few revolutions of the spinhead.Moreover, the term “strand” is used to refer to the feed or continuouslength of elastic whereas the section or segments applied to the elasticcomposite may be referred to as “elastic elements.” A “section” ofelastic is referred to herein as the length (i.e., the end length)outside of, fed by, the arms or eyelets of the spinhead and is spun bythe spinhead.

FIG. 17A reproduces, in an alternative view, the elastic composite 210depicted in FIGS. 2A, 2B, and 3. Although shown in the stretch state,the elastic composite 210 has a fixed width DD in the lateral directionand a predetermined cut length EE along the longitudinal direction.During the manufacturing process, a continuous web of the elasticcomposite 210 is delivered as output, having continuous longitudinallydirected side edges 210 a, 210 b and a central elasticized region 214 inwhich an elastic construction is situated. Extending laterally from theelasticized region 214 are non-elasticized regions 216 and 218 (alsoreferred to herein as “dead zones”). The elastic composite 210 includesa top layer 218, a bottom layer 220, and a plurality of elastic elements322 sandwiched therebetween. The top and bottom layers 218, 220 providedin most, if not all, of the examples in these descriptions arepreferably nonwoven. It is contemplated, however, that other materialsmay also be used, including a variety of textile materials, fabrics, andthe like.

As previously described in detail, the elastic element 322 extendsgenerally along a direction generally perpendicular to the longitudinalor machine direction and are spaced apart from one another by agenerally fixed distance n or pitch. The pitch n is directly related tothe manufacturing process settings and may be calculated as follows:${n({mm})} = \frac{( {{speed}\quad{of}\quad{conveyor}\quad( {m\text{/}\min} )} )}{( {{rotational}\quad{speed}\quad{of}\quad{spinhead}\quad({rpm})} )}$

FIG. 17B depicts an exemplary sheet of elastic composite 1710 accordingto the present the invention. The elastic composite 1710 has beenmanufactured in accordance with a single strand dual path method. Theelastic composite 1710 includes sections and components that areidentical to those of the elastic composite 210 in FIG. 17A, with theexception of a central elasticized region 1714. Sandwiched between a toplayer 1718 and a bottom layer 1720 are a plurality of spaced-apart,laterally extending elastic elements 1722. In this embodiment, thedistribution of elastic elements 1722 is alternately provided by a firstelastic element 1722 a and a second elastic element 1722 b. The firstand second elastic elements 1722 a, 1722 b differ in that one is fedfrom a source different from the source of the other. As will be furtherexplained below, the sources are preferably a first continuous elasticstrand and a second distinct, continuous, elastic strand. Typically, thetwo continuous elastic strands are of the same material type and havethe same material properties, but may be varied, in further embodiments,to impart specifically targeted elastic properties to the elasticcomposite 1710. The two elastic strands may also differ in thickness(see e.g., FIG. 29B as described below), as well as or in lieu ofvarying elasticity. One of the elastic strands may even be a type ofactivated elastomer (e.g., heat activated). Further, the two elasticstrands may have a different color to achieve a specific aestheticdesign, for example. Thus, the method according to the present inventionprovides some flexibility in the functional and aesthetic design of theelastic composite.

The elasticized region 1714 includes an arrangement consisting ofalternating first and second elements 1722 a, 1722 b that are spacedapart by a generally fixed distance or pitch n′. This pitch n′ isreduced from the pitch n in the previous elastic composite 210 (see FIG.17A), thereby providing for a greater elastic density across theelasticized region 1714. As will be further described below, the twoelastic elements 1722 a, 1722 b are distributed onto the web or nonwovensubstrate preferably from opposing sides of the spinhead. For everyrevolution of the spinhead, two strands of elastic elements 1722 a, 1722b are delivered onto the web. Employing an MSDP method, the value of n′may be calculated one half of that obtained by the SSSP method (assumingthat the speed of the nonwoven conveyor and spinhead are maintained atthe same speed as before):${n^{\prime}({mm})} = \frac{( {{speed}\quad{of}\quad{conveyor}\quad( {m\text{/}\min} )} )}{2 \times ( {{rotational}\quad{speed}\quad{of}\quad{spinhead}\quad({rpm})} )}$

In an alternative embodiment, two elastic strands are distributed fromthe spinhead at locations less than 180° apart (phase separation in onespin revolution), as shown in FIG. 29A, for example. In this way, thepitch between elastic elements may be varied. FIG. 29B depicts anexemplary web substrate 2960 whereon a plurality of first elasticelements 2922 a and second elastic elements 2922 b are applied on amoving first input web W1. The distribution of elastic elements providesan alternating sequence of first elastic element—second elasticelement—first elastic element on the web substrate 2960. The first andsecond elastic elements 2922 a, 2922 b are provided by, and arediscrete, severed portions of, different elastic strands. In thisexample, the first elastic element 2922 a has a greater thickness thanthe second elastic element 2922 b. Moreover, the distribution of elasticelements provides for different or alternating pitch between successiveelastic elements in the sequence. The elastic elements 2922 a, 2922 bare alternately separated by a pitch of n1 and a pitch of n2. In thisdepicted example, the larger pitch n2 is three times greater than thepitch n1. As will be further explained below, this alternating pitchsequence may be achieved by providing a spinhead 2917 such as thespinhead 2917 illustrated in FIG. 29A. The spinhead 2917 has a pair ofeyelets 2917 b, 2917 b′ for distributing a first continuous strand W anda second continuous strand W′ respectively. The eyelets 2917 b, 2917 b′are separated by a distance of 90° (followed by a separation of 270° inthe opposite direction). In providing eyelets that are not generallydiametrically opposed about the spinhead, design provisions arepreferably made to provide balance to the spinning spinhead.

As comparison, FIG. 30 provides a front view of a spinhead 3017 whereina pair of strand dispenser eyelets 3017 b, 3017 b′ are diametricallyopposed and thus, separated by 180° (spin phase revolution). The eyelets3017 b, 3017 b′ are therefore equidistantly spaced from each other ineither direction. Operation of this spinhead 3017 generates a web output30360 whereon each successive pair of elastic elements 3022 a, 3022 bare ultimately separated by a pitch n, as discussed previously.

FIG. 18A depicts an elastic composite 210′ manufactured in accordancewith the method previously described in respect to the system of FIG.15. Specifically, the elastic composite 210′ is manufactured by an MSSPmethod. The elastic composite 210′ includes sections and components thatare generally identical to those of the elastic composite 210 in FIG.17A, with the exception of the elasticized region 214′. The elasticizedregion 214′ is composed of discrete groups 322′ of multiple elasticelements that extend generally in the lateral direction. The center ofthe groups 322′ of elastic elements are spaced apart from one another ingenerally parallel relation by the same fixed distance n (from FIG. 17)(a center-to-center distance). In accordance with the method previouslydescribed in respect to the system of FIG. 15, a group 322′ of elasticstrands is delivered to the web upon each revolution of the spin head.In the elastic composite 210′ depicted in FIG. 18A, the groups 322′consist of two adjacent elastic elements.

FIG. 18B depicts an exemplary elastic composite 1810 according to afurther embodiment of the present invention. The elastic composite ismanufactured by an MSDP method, in accordance with an alternativeembodiment of the present invention. The elastic composite 1810 includessections and components that are generally identical to those of thethree previously described elastic composites 210, 1710 and 210′, withthe exception of the elasticized region 1814. In this exemplary elasticcomposite 1810, two different groups of elastic strands 1822 a, 1822 bare delivered onto the web upon each revolution of the spinhead. Thelateral centerlines of the groups 1822 a, 1822 b are spaced apart by thesmaller pitch n′—as with the elasticized region 1714 in FIG. 17B.Assuming that one type of elastic element is used for the elasticcomposites in each of FIGS. 17A, 17B, 18A, 18B, the resultingelasticized region 1814 in this embodiment imparts a greater degree ofelasticity to the elastic composite 1810 than any of the otherarrangements. A higher elastic density is achieved by both providing fora smaller fixed distance, n′, between the individual elastic elements orgroups and providing for more elastic elements at application by thespin head. Furthermore, the speed of the operation is increased from theoperation associated with each of the elastic composites in FIGS. 17Aand 18A.

It should be noted that the elastic elements within each of the twogroups 1822 a, 1822 b may be varied or may be of one type. Further, theconstituents of the other two groups may be different or identical.

The elastic elements are directed generally perpendicular to thelongitudinal or machine direction. Further, the elastic elements arestructurally independent of each other, although in some embodiments maybe of (i.e., severed sections) one or more elastic strand. In FIG. 17A,for example, all of the elastic elements are elastic elements of asingle, continuous strand, although, in the composite, the elasticelements are structurally independent. Furthermore, each elastic elementgenerally does not have a vertical (or longitudinal) component. As aresult, a certain uniformity in horizontal elasticity is achieved. Insome embodiments, this characteristic provides an elongated elasticcomposite that does not tend to twist or kink when at rest, and at rest,is more uniform and aesthetically pleasing.

Table 2 below summarizes some of the benefits and advantages attained bythe different manufacturing methods discussed above. To facilitate thecomparisons, the number of elastic elements per unit of linear lengthprovided by the four methods is the same. Thus, the tensile and elasticproperties of the output elastic composites are similar. TABLE 2Manufacturing method SSSP MSSP SSDP MSDP Number of elastic elements 1 22 4 applied per revolution Machine output 40 m/min 80 m/min 80 m/min 160m/min Spinhead speed = 8000 rpm Elastic elements per linear meter = 400Pitch (separation of elastic 2.5 mm 5 mm 2.5 mm 5 mm strands) Examplesof Advantages — *Efficiency: Aesthetic: Efficiency: Output Pitch is ½ ofOutput Increased by that for MSSP Increased by 100% Efficiency: 300%over Output SSSP Increased by 100% over SSSP*Formula for machine efficiency:Output (m/min) = spinhead speed (rpm) × no. of elastic elements appliedper revolution × pitch × 2.

Table 2 illustrates the design and operational flexibility attainablethrough employment of the various methods previously described. As willbecome apparent to one skilled in the art provided with the presentdisclosure, certain methods may prove more useful than others dependingon the particular design and operational requirements. In this regard,attention is now directed to the systems available to implement thesemanufacturing methods.

With reference to FIGS. 19A and 19B, a method of making an elasticcomposite of the invention utilizing a dual path method is nowdescribed. The inventive method is described in conjunction with adescription of an exemplary system 1901 of making the elastic composite.

FIGS. 19A and 19B depict a system 1901 and system components, andillustrate a method of making an elastic composite (e.g., elasticcomposite 1710 or 1810) according to the present embodiment. The systemand its components are substantially similar to those previouslydescribed. The differences between the previously described systems andthe system 1901 of FIGS. 19A, 19B represent improvements provided by thepresent invention. These differences will be the focus of the followingdescription.

For purposes of the present description, references will be made toupper and lower relative positions, as well as right and left directionsand positions. It will be understood by one skilled in the art thatthese positional and directional references are made for descriptiononly, and that the invention is not to be limited by their use. Further,it will become apparent that variations of the system and process may bemade, utilizing different positions and directions for the varioussystem components and feeds.

For the most part, the system 1909 includes the same componentsprovided, for example, in the system depicted in FIGS. 11-16. The system1901 includes a conveyor assembly 1909 for receiving, manipulating, andconveying each of the two nonwoven web inputs. The conveyor assembly1909 is positioned next to, and operatively associated with, an elasticelement applicator in the form of a spinning head assembly 1907. Thespinning head assembly 1907 is operable to apply elastic fibers orstrands upon, onto, and/or integrally with an input web of nonwovenconveyed by the conveyor assembly 1909. The spinning head assembly 1907further includes a spinhead 1917, preferably in the form of a spinningbracket or cylinder 1917 (spinhead). The spinhead 1917 is configured tohold an “end section” of the continuous strand WW of elastic element andmove it about a generally vertical plane XX in a reciprocal orrepetitive manner (relative to the conveyor assembly 1909). As describedpreviously, this plane XX is defined by the area within the spinningperimeter of the cylinder 1917 that is traced by the outer-most bracketor eye 1917 b securing the continuous strand WW to the spin cylinder1917. It is understood that the vertical plane XX need not be at 90° tothe web platforms U, L (and thus, to the web plane moving direction),but it is generally preferred. The path of the spinning head 1917 andthe section of elastic strand retained thereby are provided on the planeXX. In FIG. 19A, the section of strand WW between the eyelet 1917 b andthe platform U is indicative of a linear portion of the plane XX.

Referring also to FIG. 21A, the conveyor assembly 1909 includes an upperconveyor or web moving platform U (web platform U) provided by amovable, continuous belt U1 and a series of rollers supporting the beltU1. The conveyor assembly 1909 further includes a lower conveyor or webmoving platform L (web platform L) also provided by a movable,continuous belt L1 and a series of rollers supporting the belt L1. Inthe side view of FIG. 19B, the lower belt L1 is positioned in generallyparallel relation with the upper belt U1 and vertically spaced therefromby a distance or gap HH. Although the belts U1, L1 are designed forreciprocal motion during system operation, the belts U1, L1 may bedescribed as having a planar outside deck or surface S1, S3 and a planarinside deck or surface S2, S3 at any fixed point in time (for purposesof the present description). The use of “inside” and “outside”references are made in view of the relative locations of the surfaces(i.e., facing outside of the assembly 1909 or facing inside the assembly1909). This use of such references is provided to facilitate thedescription only, and should not be construed as a limitation on theinventive system and method.

As represented in the plan view of FIG. 19B, each of first and secondprimary inputs webs W1, W2 provide a web of nonwoven utilizing a seriesof rollers and guides. The two webs W1, W2 are first directed throughfolding guides or plates, which serve to effectively reduce the overallwidth of the nonwoven web by folding the ends or side edges along apredetermined, longitudinally extending side fold line. As previouslydescribed, the input webs W1, W2 are directed centrally into the gap HHbetween the upper and lower web platforms U, L, along a first web planemoving direction, MM and toward the spinhead 1917. This first web planemoving direction MM also corresponds to a direction from right to leftin the side view of FIG. 19B. This first web plane moving direction MMalso directs the nonwoven inputs 1903 a, 1903 b toward the center of thespinhead 1907. Once inside the spinhead 1917, the conveyor assembly 1909reverses the direction of travel of the input webs W1, W2 (a turn of 180degrees), from the first web plane moving direction MM to the oppositelydirected second web plane moving direction NN. The second web planemoving direction NN is identical (orientation) to the first web movingplane moving direction MM, except that the directions are reversed.

As the input webs W1, W2 exit the spinhead 1917, a first elastic strandWW is wrapped around the entire conveyor assembly 1909 and contacts theoutside surfaces S1, S3 of the belts U1, L1, respectively. The firstelastic strand WW also comes into contact with the moving webs W1, W2.The elastic strand WW is applied crosswise or laterally on the web, andtransverse to the second web plane moving direction NN. As explainedpreviously, this transverse direction is also the cross-machinedirection. Friction between the elastic strand WW and the input webs W1,W2 on the belt surfaces S1, S3, helps to draw the “wrapped” elasticstrand WW out of the spinhead 1917.

As already described, the system 1901 positions a first elastic inputsource E1 on the left side of the system 1901 (in the views of FIGS.19A, 19B). The input source may be in the form of a spool of elastic.The continuous first elastic strand WW is delivered through a hollowshaft in a motor that controls the spinhead 1917. The elastic strand WWthen passes into the spinhead 1917 and is guided by rollers, eyes, orother suitable means, around the inside of the cylinder of the spinhead1917.

In this particular embodiment of the present invention, the system 1909further employs a second elastic input source E2 that is, in the viewsof FIGS. 19A, 19B, positioned on the right side of the system 1901. Asecond continuous elastic strand WW′ may be delivered via any suitablesystem of rollers and eyes, centrally along the gap HH and into the openend of the spinhead 1917. Upon exiting the gap HH, the second continuouselastic strand WW′ is directed across the center of the spinhead 1917and to the back of the spinhead 1917. The second continuous elasticstrand WW′ is then guided by rollers, eyes, or other suitable means,around the inside face of the cylinder, to an eyelet 1917 b′ positioneddiametrically opposite (180°) of the eyelet 1917 b of the firstcontinuous elastic strand WW. Thus, the first and second elastic strandsWW, WW′are separated by 180°, within the spin cylinder. By takingopposite paths around the spinhead, the risk of entanglement between thetwo continuous elastic strands WW, WW′ is substantially alleviated.Further, the elastic strands WW, WW′ are preferably tensioned by passingthe continuous strand through any suitable tensioning unit prior tobeing received by the spinhead 1917.

As the spinhead 1917 is spun around the upper and lower platforms U, L,sections of the first and second elastic strands WW, WW′ are appliedsimultaneously about the two web moving platforms U, L. Referring to theexemplary spinhead 1917 of FIGS. 19A and 19B, the eyelet 1917 b′ for thesecond elastic strand WW′ is shown at a position slightly forward of theeyelet 1917 b of the first elastic strand WW. Preferably, the eyelets1719 a, 1719 b are not separated as such, but aligned so as to provide acommon vertical plane XX. The mis-alignment depicted in FIGS. 19A, 19Bare provided primarily to best show the distribution of elastic strandsWW, WW′ about the conveyor assembly 1909.

It is contemplated, however, that certain other applications may be bestimplemented by positioning one eyelet forward of the other, as shown. Insuch an application, the generally vertical plane XX, about which thefirst elastic strand WW is spun, is slightly left of a second generallyvertical plane XX′ (not shown), about which the second elastic strandWW′ is spun. The two vertical planes XX, XX″ are disposed in mutualparallel relation and both intersect the upper and lower platforms U, L.The elastic elements WW, WW′ are applied onto the moving webs at theselinear intersections of the vertical planes XX, XX′ with the beltsurfaces S1, S3 (i.e., along the web path of the nonwoven webs). Thepositions of the eyelets 1917 b, 1917 b′ may be adjusted to achieve thedesired pitch n′ discussed above.

In a further embodiment initially described in respect to FIGS. 29A,29B, the position of the eyelets 1917 b, 197 b′ are not diametricallydisposed but positioned less than 180 degrees apart. In this way, thepitch between elastic elements may be adjusted to satisfy designrequirements. The eyelets 2917 b, 2917 b′ in FIG. 29A are positionedabout 90 degrees apart in one direction and about 270 degrees in theopposite direction. Operation of the spinhead 2917 provides for a websubstrate 2960 whereon the elastic elements 2922 a, 2922 b (from elasticstrands W and W′, respectively) are separated by alternating pitchdistances of n (n1) and 3 n (n2).

FIGS. 20A and 20B depict an alternative system 2001 (to the system 1901of FIGS. 19A and 19B) for making the elastic composite according to theinvention (wherein like reference numerals are used to indicate likeelements). In this embodiment, a bracket system 2090 of tensioningrollers is provided proximate the end of the web platforms U, L and theend of the gap HH. The bracket system 2090 directs the second continuouselastic strand WW away from the centerline AA of the spinheadmomentarily to avoid front rollers 2084. The bracket system 2090 may besupported or suspended between the upper and lower web platforms U, L,and in between the input webs W1, W2, by any suitable means.

Returning to FIGS. 19A and 19B, further description of the inventionsystem and method will now be provided, particularly that of theintersection between the primary input webs W1, W2, continuous strandsWW, WW′, and secondary input webs W3, W4. FIGS. 21A-21D providecross-sectional views through the system 1901 depicted in FIG. 19. Thesesimplified views are provided to illustrate certain points in theprocess of applying elastic elements onto the nonwoven webs. Referringto FIG. 21A, a first cross-sectional view also is presented proximatethe ends of the two web platforms U, L. The view reveals cross-sectionsof the two continuous belts U1, L1. This view includes cross sectionsshowing outside belt surfaces S1, S3, and inside belt surfaces S2, S4.As viewed in FIG. 21A, the two inside belt surfaces S2, S4 move out fromthe page along the first web plane moving direction MM and convey theinput webs W1, W2 into the spinhead 1917. The two outside surfaces S1,S3 move into the page along the second web plane moving direction NN andconvey the webs W1, W2 away from the spinhead 1917. The input webs W1,W2 of nonwoven are shown on the belts U1, L1 with their ends alreadyfolded.

As used herein, the term “web plane path” shall mean the path (includingdirection) taken by the input webs W1, W2 as conveyed by the conveyorassembly 1909. For one input web, the “web plane path” includes the pathalong the inside surface S2 of the continuous belt U1 directed along thefirst web plane moving direction MM and the path along the outsidesurface S1 of the same belt U1 directed along the second web planemoving direction NN. The web plane path of the other input web isdifferent from the first web plane path, although it is also directed,in certain segments of the path, in the same web plane moving directionsMM or NN. As described herein, the vertical plane XX, XX′ intersects theweb plane path on the outside belt surface S1 and along a transverseline common with the web plane path.

Referring to FIG. 21B, a cross-sectional view is provided across asection further away from the spinhead. At this point in the process,the spinhead 1917 has applied several sections of the first and secondcontinuous elastic strands WW, WW′ about the conveyor assembly 1909, andmore specifically, over the input webs W1, W2. In doing so, the spinhead1917 has applied the continuous elastic strands WW, WW′ transversely inrespect to the second web plane moving direction NN.

Referring to FIG. 21C, a cross-sectional view is provided across asection downstream of the rollers for the third and fourth input websW3, W4 of nonwoven. The rollers facilitate the application of a secondweb layer upon each substrate that now includes the elastic elements anda first nonwoven web. In this manner, a moving web of elastic compositeis produced consisting of a top layer of nonwoven sheet, a base layer ofnonwoven sheet, and elastic elements sandwiched therebetween. At thispoint, the ends of the input webs W1, W2 are still folded around theends of the belt surfaces S1, S3. The view of FIG. 21C also indicatesthe locations of knife mechanisms KK where the elastic strands WW, WW′are cut immediately downstream of the cross-sectional view. As discussedpreviously, the cuts may be provided by knife structures locatedadjacent the web platforms U1, L1.

The cross-sectional view of FIG. 21D represents a point furtherdownstream in the process. In this view, the continuous elastic strandWW, WW′ has been cut to provide a distribution of segmented elasticelements 1722 within the web substrate. Every other segmented elasticelement 1722 in the distribution is characterized as having originatedfrom the same first or second continuous elastic strand. Further, eachpair of adjacent or sequential elastic element 1722 are characterized ashaving originated from a different continuous elastic strand. This viewalso reveals that the first and second input webs 1903 have beenunfolded, in a manner described previously. FIG. 21D depicts, therefore,a cross-section of web outputs O1, O2 of the system and method ofmanufacture, according to the invention.

FIG. 22 provides a simplified flow chart of the basic steps of a methodof making an elastic composite, in accordance with the presentinvention. The flow chart 2210 also provides a summary of the processdescribed in respect to FIGS. 19-21. The basic steps of the method arepreferably performed through operation of a system such as the exemplarysystems 1901, 2101 of FIGS. 19 and 20. In an initial step 2210, a firstweb of material (e.g., a nonwoven layer) is conveyed along a web planepath. The web plane path is simply a path along which a web having anexpanse (i.e., width and substantial length) may be conveyed. The webplane path is preferably controlled by a fixed system to provide aconsistent path for a moving, continuous web, directed along apredetermined web direction (which is planar). As illustratedpreviously, the web plane path is generally predetermined, in thepreferred embodiment, by the web platforms of a conveyor assembly andthe conveying step 2210 is implemented through operation of the webplatforms. A section of a first continuous elastic strand is thenapplied onto the first web and generally transversely to the web planepath (Step 2214). Further, a section of a second elastic strand isapplied onto the second web and generally transversely to the web planepath (Step 2218). These steps 2214, 2218 are preferably performedthrough operation of a single spinhead that spins the two strands aboutthe first web being conveyed and about a plane(s) that intersects themoving web. By repeating the applying steps while performing theconveying step, a plurality of sections of the first and second elasticelements is arranged on the first web in generally parallel relation(Step 2222). As previously explained, this plurality of elastic elementsdistributed longitudinally along the web and in mutual parallel relationprovides an elasticized region in the web output and in each individual,finished elastic composite product, according to the present invention.

FIGS. 23-27 depict a system and system components, and illustrate amethod of making an elastic composite according to another embodiment ofthe invention. Again, the depicted system and its components aresubstantially similar in structure and operation to those previouslydescribed. Applicable detail descriptions of the system components andoperation may be borrowed from earlier portions of this disclosure.Differences between the previously described systems and the systems tobe described represent or arise from improvements provided by thepresent embodiment. Such differences are discussed herein in moredetail.

FIG. 23 provides a plan view of the inventive system 2301. FIG. 24provides a perspective, isometric view that reveals several of thecomponents of the inventive system. Directional arrows are providedthroughout FIG. 24 to indicate the movement of conveyors, web ofmaterials or elastic composites, the spinhead assembly, and the like.

In this particular set of embodiments, a system provides and a method isimplemented for making an elastic composite, whereby a continuous strandof elastic is applied onto a first and a second web along a directiongenerally transverse to a web plane moving direction. In theseembodiments, the first and second input webs are conveyed along the webplane moving direction. This means that a plane may be extended from(and including) one web into (and including) the other web, and the twowebs move along that plane in the same direction (i.e., paralleldirectional vectors, such as 90 degrees horizontally and vertically ofthe vertical plane XX). The two moving webs are, therefore, generallycoplanar about the locations or sections whereupon a section of theelastic strand is applied to both webs. Moreover, the section of elasticstrands is applied generally “linearly” onto both the first and secondwebs. As used heretofore, this reference to the section of strand beingapplied “generally linearly” means that the applied section generallyprovides a linear segment that extends across the planes of both thefirst and second webs and includes a shorter linear segment on each ofthe first and second webs.

Referring to FIGS. 23 and 24, as well as the cross-sectional view ofFIG. 25A, a system 2301 is provided to implement the inventive methodand produce a web output O1 of inventive elastic composite andpreferably a second web output O2. A conveyor assembly 2309 is providedhaving a web platform U and preferably a second web platform L (foroutputting second web output O2). In this embodiment, an upper webplatform U is positioned above, and generally aligned with, a lower webplatform L. Each web platform U, L is referred to as having a pair ofconveyors in the form of movable continuous belts. Referringspecifically to the cross-sectional view of FIG. 25A, a left continuousbelt U 1 of the upper platform U is spaced laterally from a secondcontinuous belt U2. Lower web platform L also has similarly positionedleft continuous belt L1 and right continuous belt L2.

The continuous belts U1 and U2 are referred to as having, at any givenpoint in time, an inside deck or surface S3, S4 that is moving towardthe spinhead 2317 (in the web plane moving direction MM) and an outsidedeck or surface S1, S2 that is moving away from the spinhead 2317 (inthe web plane moving direction NN). As will be further described below,the outside surfaces S3, S4 are generally co-planar or at leastcorresponding sections of the surfaces S3, S4 are, such that sections ofinput webs supported on the corresponding sections are co-planar andpositioned to receive a section of elastic strand that extends linearlyacross the two webs. Similarly, continuous belts L1, L2 have insidesurfaces S7, S8, which are moving toward the spinhead 2317, and outsidesurfaces S5, S6, which are moving away from the spinhead. Accordingly,the pair of inside surfaces for each web platform may be referred to asbeing generally disposed on the same imaginary, extended plane and thepair of outside surfaces may be referred to as being generally disposedon another imaginary, extended plane. In these preferred embodiments,the two imaginary, extended planes are spaced vertically apart andgenerally disposed in parallel relation. Thus, S1 and S2 are generallyon the plane, as are S3 and S4, S7, and S8, and S5 and S6. The pairs ofcontinuous belts are, therefore, operable to convey a pair of input websalong a predetermined web plane path, first along a first web planemoving direction toward the spinhead and a second, reversed, web planemoving direction away from the spinhead. It is preferred, of course, toconvey the pair of input webs at the same time.

An elastic applicator assembly 2307, including a spinhead 2317, in thisembodiment, has a construction that is consistent with that previouslydescribed in respect to FIGS. 10-13. It will be apparent, however, thatsizes and dimensions may be different to accommodate the dual webplatform assembly. In any event, a single input source E1 of acontinuous elastic strand WW is provided and received by a motoroperatively associated with the spinhead described before. The spinhead2317 includes arms as described previously, and a series of rollers andeyelets for routing and applying the continuous elastic strand WW aboutthe conveyor assembly 2309 and about the generally vertical plane XX.

Referring now to FIG. 24, this exemplary system is provided with fourindependent sources of a primary input web of nonwoven: a first inputweb W1 arriving from an upper part of the system; a second input web W2lower web arriving also from an upper part of the system; a third inputweb W3 generally below the first input web W1; and a fourth input web W4generally below the second input web W2. Each of the four primary inputwebs W1-W4 is preferably processed through a folding mechanism, asdescribed previously. The four input webs are then moved along a firstweb plane moving direction MM and in between the upper and lower webplatforms U1, L1. Movement of the input webs is, of course, driven bythe four continuous belts U 1, U2, L1, L2.

The exemplary system is further provided with an upper secondary inputweb W5 of nonwoven positioned above the conveyor assembly 2309 forapplying a base layer simultaneously to a pair of elasticated substratesas will be described below. Similarly, a lower secondary input web W6 isprovided for applying a base layer, as will also be discussed below.Finally, a pair of large rollers 2342, 2344 is positioned downstream ofthe conveyor assembly 2309. Each roller serves to output a web O1 or O2of elastic composite from the system. For this exemplary system andprocess, that web output O1, O2 will provide a dual-elasticized elasticcomposite 2322 according to the invention.

Each of FIGS. 25A-25C provides a cross-sectional view through variouspoints in the process and through sections of the system depicted inFIG. 23. The cross-sectional view of FIG. 25A is placed to highlight thetwo web platforms U, L, the four continuous belts U1, U2, L1, L2, andthe four input webs W 1-W4 conveyed thereon. The four webs W1-W4 areconveyed in a direction coming out of the page and toward the spinhead(i.e., first web plane moving direction MM). As also shown in FIG. 25A,the ends of the input webs W1-W4 enter the spinhead 2317 in a foldedconfiguration.

The cross-sectional view of FIG. 25B is provided downstream of thespinhead 2317 and of the vertical plane XX. Thus, an elastic strand WWis applied continuously about the conveyor assembly 2309 and upon eachof the four primary webs W1-W4 of nonwoven. Friction between the inputwebs W1-W4 and the applied elastic strand WW helps draw the continuousstrand WW from the spinhead 2317.

Turning to FIG. 25C, the cross-sectional view is moved furtherdownstream in the process. Specifically, the cross-section is providedat a point in the process after application of the secondary web inputsW5, W6. In one aspect of the present invention, one secondary input webis used in conjunction with the two primary input webs to create theelastic composite. A secondary nonwoven is shown applied upon thesubstrate combination of elastic elements and adjacent pair of inputwebs (W1 and W2; W3 and W4). The application of the secondary input webW5, W6 of nonwoven provides, therefore, an elastic composite. FIG. 25Calso illustrates the use of central folded section F1, F2 in eachsecondary input webs W5, W6. The secondary input web W5, W6 is folded soas to later reveal a central dead zone between two elasticized regionsof the elastic composite. This feature of the inventive elasticcomposite is discussed in further detail below.

FIG. 25C also indicates the location of a knife mechanism KK downstreamof the cross-section as discussed previously. At these horizontallocations, the knife mechanisms cut elastic strand WW, thereby severingelastic elements from the continuous strands. The cuts also separatesthe process into an upper process and a lower process. Morespecifically, the cuts separates the upper, moving substrate consistingof input webs W1, W2, secondary input web W5 and elastic elementstherebetween, from a similarly constituted lower, moving substrate.Additionally, another pair of knife mechanisms KK′ is positioned atlocations downstream of the cross-sectional view and, above, and below,the centers of the web platforms U, L. The knife mechanisms KK′ arelocated to purposefully coincide with the middle of the central foldedsections F1, F2. At these locations, the continuous elastic strand WW(or elastic element, if knife mechanisms KK′ are downstream of knifemechanisms KK) is severed to provide a left and right elastic segment orelement in the finished elastic composite. As already discussed, thisalso provides right and left elasticized regions and leaves the centralpart of the web absent of elastic elements. Thus, when the foldedsections F1, F2 is unfolded, the central dead zone is needed.

FIG. 26 provides a cross-sectional view of a finished web output of thesystem and process. Two identical web outputs O1, O2 of elasticcomposites are provided. Referring to the web O1, a first nonwoven layeris provided by the pair of primary input webs W1, W2, a second nonwovenlayer is provided by the single secondary input web W5, and a pair ofelasticized regions 2614 therebetween make up the finished elasticcomposite web. The elasticized regions 2614 are provided by adistribution of elastic elements 2622 that are in generally parallelrelation and extend laterally. The elastic elements also provide, as aresult, elasticity in the lateral direction and without a verticalcomponent. The two elasticized regions 2614 are laterally spaced fromone another to provide a dead zone 2650 therebetween. As discussedabove, the dead zone results from cutting the elastic strand WW orelastic element using the knife mechanisms KK′ and the unfolding of thefolded sections F1, F2. Dead zones are also provided between the sideedges of the nonwovens and each of the elasticized regions. The sidedead zones result partly from the unfolding of the folded ends of theprimary input webs W1-W4. These unfolding steps may be performedimmediately downstream of the two knife mechanisms in a mannerpreviously described in this disclosure.

The width of the central non-elasticized region or dead zone 2650 may becontrolled by controlling the lateral separation between the pairs ofbelts in each web platform (e.g., the space between U1 and U2 and thespace between L1 and L2). It may also be controlled by specifying thewidth of the excess fold in the center of the secondary web. This foldis configured to retain some of the material away from the compositeduring the process and is typically opened up downstream to reveal thecentral non-elasticized region or dead zone.

In an alternative embodiment, the system 2301 and method are modified toproduce four web outputs and four separate elastic composites, accordingto the present invention. In one variation, the knife mechanisms KK′ maybe modified to also sever the secondary input webs W5,W6 (in addition tothe elastic strand WW). In this way, each of the two web substrates isdivided to produce an independent elastic composite to the left and alsoto the right of the knife mechanisms KK′. Each elastic composite has asingle central elasticized region and two side dead zones. In the methodto create the pairs of elastic composites, the width of the foldedsections F1, F2 may be provided to correspond with the folded ends ofthe primary input webs.

In yet another alternative embodiment, four independent secondary inputwebs are used instead of two. Each secondary input web joins with aprimary input web, with elastic elements, thereon, to produce an elasticcomposite having a centralized region. The elastic composite also has apair of dead zones on either side of the central elasticized region.

FIG. 27 provides a simplified flow chart of the basic steps of a methodof making an elastic composite, in accordance with this embodiment ofthe present invention. The flow chart 2700 also summarizes the processdescribed above in respect to FIGS. 23-25. The basic steps of the methodare preferably performed through operation of a system such as theexemplary system 2301 in FIGS. 23 and 24.

In initial steps 2710, 2714, a first web of material is conveyed along aweb plane moving direction and a second web of material is conveyedalong the web plane moving direction. Preferably, the web plane movingdirection is predetermined by the web platforms of a conveyor assemblyand the conveying steps 2710, 2714 are implemented through operation ofthe web platforms. A section of a first continuous elastic strand isthen applied generally linearly onto both the first and second websalong a direction generally transverse to the web plane moving direction(Step 2718). The applying step 2718 is preferably performed throughoperation of a spinhead that spins the elastic strand about the firstand second webs as these webs are conveyed along the web plane movingdirection. Preferably, the applying step 2718 is performed whileperforming the conveying steps 2710, 2714 such that a plurality ofsections of the first and second elastic elements are arranged on eachof the first web and the second web in generally parallel relation. Theelastic elements are distributed longitudinally along the web and inmutual parallel relation, so as to provide, in the finished elasticcomposite, an elasticized region. In one embodiment, the first andsecond webs provide a top or base layer and the first and secondarrangements of elastic elements provide the pair of elasticizedregions.

Each of FIGS. 28A-28C illustrates an elastic composite 2810 containing apair of elasticized regions 2814 and three non-elasticized zones or deadzones, including a central dead zone 2850 extending longitudinallybetween the two elasticized regions 2814 and side dead zones 2816, 2818on the other side of each elasticized region 2850. The elastic composite2810 may be referred to herein as a dual-elasticized elastic composite.In FIG. 28A, the elastic composite 2810 shown is formed from twodiscrete composite sections C1, C2. Each composite section C1, C2 ismanufactured independently as a discrete elastic composite having asingle elasticized region. Any one of the three methods described hereinmay be employed to make the singly elasticized composite section. Toform the dual-elasticized elastic composite, two of the singlyelasticized composite sections are joined together by overlapping oneside edge of one composite section over a side edge of the othercomposite section. A suitable adhesive or adhesive means may be used tomaintain bonding at the overlap. The overlap creates a multi-layerbonding portion B as shown in FIG. 28A, which also serves as a portionof the central dead zone.

The bonding portion B consists of a top nonwoven layer 2818 and a baselayer 2820 of each composite section. Accordingly, the thickness of thebonding portion B and the central dead zone 2850 may be significantly,or at least observably, greater than the thickness of the rest ofdual-elasticized elastic composite. For each composite section C1, C2,the top nonwoven layer 2818 and the base nonwoven layer 2820 have thesame width and the side edges are aligned.

Turning to FIG. 28B, a second dual-elasticized elastic composite 2810′is shown again consisting of two adjoined singly elasticized, compositesections C1′, C2′. For each composite section C1′, C2′, one of a toplayer 2818′ and a bottom layer 2820′ is wider than the other. Referringto the view of FIG. 28B, the right composite section C2 has a bottomlayer 2820′ that extends laterally farther than the top layer 2818′,thereby forming a step. For the left composite section, the top layer2818′ extends laterally farther than the bottom layer 2820′, therebyforming a ledge. By abutting the ledged side edge to the stepped sideedge, a suitable construction joint is provided between the twocomposite sections C11′, C2′. An overlapping bonding portion B′ (andcentral dead zone 2850′) is also provided that consists of a single toplayer 2818′ and a single base layer 2820′ and is characterized by athickness generally consistent with the other portions of the dualelasticized elastic composite 2810′. A suitable adhesive or adhesivemeans may be employed to facilitate and maintain bonding between thelayers of the bonding portion.

FIG. 28C illustrates an improved dual elasticized elastic composite2810″ that may be manufactured in accordance with the method describedin respect to FIGS. 23-26, in accordance with the present invention. Inaddition to a pair of elasticized regions 2814″, the elastic compositealso has two side dead zones 2816″ and a central dead zone 2850″situated between the elasticized regions 2814″. The thickness of thedead zone 2850″ is provided by a single top layer 2818″ and a singlebase layer 2820″ and is, therefore, consistent with the thickness ofother portions of the dual elasticized elastic composite 2810″. In oneaspect of the present invention, the dual elasticized elastic composite2810″ provides a single composite structure. The base layer 2820″ of theelastic composite 2810″ is provided by a seamless sheet of nonwoven (orother material). The elastic composite 2810″ does not require joining oftwo discrete elastic composite sections. Rather, a web of the dualelasticized elastic composite 2810″ is generated linearly as output ofthe method described in respect to FIGS. 23-27. A seamless compositestructure, the dual elasticized composite 2810 eliminates the bondingregion required of the elastic composites in FIGS. 28A and 28B and thus,avoids the potential for leakage generally associated with these bondingregions B, B′. The seamless composite structure is also morestructurally sound than the other composites and has a higher tensilestrength (laterally and longitudinally).

As used herein, the term “seamless composite structure” shall refer to astructure that does not have a seam at which two or more originallyindependent sections are joined as one to form the present structure. Itshould be noted that the top layer 2818″ of the elastic composite 2810in FIG. 28C may provide a single seam S″ along the central dead zone2850″ and thus, may not be referred to as “seamless.” This seam S″ ofthe top layers 2818″ is not, however, a seam of the elastic composite2810″ as that seam S″ does not extend through the thickness of the deadzone 2850″ and the multi-layer composite 2810″, and is not required tojoin two independent sections of the elastic composite 2810″.

As expected, the dual elasticized elastic composite 2810″ is generallyeasier to manufacture than the other composites in that it does notrequire the joining and bonding steps required described previously. Italso does not require the machines or manpower to implement these steps.Furthermore, the seamlessness of the elastic composite 2810″ isgenerally more aesthetically pleasing than the bonding regions B, B′. Byeliminating or reducing the use of adhesives, the central dead zone ofthe present elastic composite is also generally cleaner. Furtheradvantages and benefits of the dual elasticized composite according tothe invention, or of the method of making same, will be apparent to onegenerally skilled in the art.

The foregoing description of the present invention has been presentedfor purposes of illustration and description. It is to be noted that thedescription is not intended to limit the invention to the varioussystems, apparatus, and processes disclosed herein. Various aspects ofthe invention, as described above, may be applicable to other types ofdisposable absorbent articles, garments, and the like, and processes formaking the same. For example, the elastic composite described above, maybe incorporated in other disposable absorbent garments such as trainingpants, etc. or in other areas or as other components of the garment. Theelastic composite may also be incorporated into or with other garments,textiles, fabrics, and the like, or combinations thereof. Moreover, thevarious aspects of the process described in respect to FIGS. 17-30 maybe utilized to produce compositions, garments and articles other thanthose described herein. Such variations of the invention will becomeapparent to one skilled in the relevant consumer products art providedwith the present disclosure. Consequently, variations and modificationscommensurate with the above teachings, and the skill and knowledge ofthe relevant art, are within the scope of the present invention. Theembodiments described and illustrated herein are further intended toexplain the best modes for practicing the invention, and to enableothers skilled in the art to utilize the invention and other embodimentsand with various modifications required by the particular applicationsor uses of the present invention.

1-18. (canceled)
 19. A method of making an elastic composite forincorporation into a disposable absorbent garment, textile or fabricstructure, and the like, said method comprising the steps of: conveyinga first web of material along a first web plane moving path; conveying asecond web of material along a second web plane moving path generallyparallel with the first web plane moving direction; and applying asection of a continuous strand of elastic element generally linearlyonto both the first web and the second web along a direction generallytransverse to said web plane moving paths.
 20. The method of claim 19,wherein the first and second webs being conveyed along the first andsecond web plane moving paths, respectively, are spaced laterally apartsuch that the section of elastic strand is applied along a transverseline extending across the first web and the second web.
 21. The methodof claim 19, wherein said conveying steps include positioning the firstand second webs such that the first and second webs are generallycoplanar about sections whereupon the section of continuous strand isapplied.
 22. The method of claim 19, further comprising the steps of:moving the section of elastic strand generally about a plane; whereinsaid conveying steps includes conveying the first and second webs ofmaterial along the web plane moving paths such that the first and secondwebs are spaced laterally apart and intersect the plane, therebyapplying the section of elastic strand onto the first web and the secondweb.
 23. The method of claim 22, wherein the section of elastic strandis spun about the first and second webs during the step of moving thesection of continuous strand.
 24. The method of claim 22, wherein thesection of elastic strand is moved about the plane in a reciprocalpattern to periodically apply the section of elastic strand onto thefirst and second webs, thereby applying a plurality of elastic elementsonto the first and second webs.
 25. The method of claim 24, wherein theplurality of elastic elements are applied in generally parallel relationon the first and second webs.
 26. The method of claim 25, wherein thesection of elastic strand is applied generally perpendicular to the webplane moving paths.
 27. The method of claim 24, further comprising thestep of applying a matching web of material onto each of first andsecond webs having a plurality of elastic elements applied thereon,thereby providing a web of elastic composite comprising at least twolayers of material and a plurality of elastic strands sandwichedtherebetween.
 28. The method of claim 24, further comprising the step ofapplying a single matching web of material onto both first and secondwebs having a plurality of elastic elements applied thereon, therebyproviding a web of elastic composite comprising a single layer ofmatching web, laterally spaced layers of first and second webs, and aplurality of elastic strands sandwiched therebetween.
 29. The method ofclaim 24, further comprising the step of cutting the elastic strandbetween the first and second webs, thereby providing a web substratehaving a pair of spaced apart longitudinally extending elasticizedregions and a non-elasticized region therebetween.
 30. A system formaking an elastic composite for incorporation into a disposableabsorbent garment, textile, or fabric structure, and the like, saidsystem comprising: a web conveyor assembly including a first web movingplatform for moving a first web thereon and a second web moving platformfor moving a second web thereon; and a spinning head assembly forapplying a section of a first continuous elastic strand about said webplatforms and the first web and the second web being moved therealong,said spinning head assembly being positioned about said first and secondweb moving platforms to spin said section of elastic about a planeintersecting said first and second webs moving therealong; and whereinsaid first and second web moving platforms are spaced laterally apart.31. The method of claim 29, wherein the step of applying a singlematching web includes providing a fold centrally along the singlematching web before applying the matching web on the first and secondwebs, comprising the step of unfolding the central fold after saidcutting step to reveal a central non-elasticized region.
 32. The methodof claim 24, further comprising the step of cutting each applied sectionof elastic element proximate each lateral side edge of the first andsecond web, thereby separating each section from the continuous strandand leaving a segmented elastic element on the first and second webs.33. The method of claim 22, wherein the section of elastic strand isapplied onto each of the first and second webs such that the sections ofelastic strand is retained thereby and the first and second webs drawthe continuous strand as the first and second web is conveyed away fromsaid plane.
 34. The method of claim 22, wherein each of the first andsecond webs is moved by a conveying platform that intersects the planeof the moving section of elastic strand.
 35. The method of claim 34,further comprising the steps of first conveying the first and secondwebs on inward faces of the platforms in an initial web plane movingdirection and then redirecting the webs to outward faces of the platformand along a second web plane moving direction opposite the first webplane moving direction upon reaching one end of the platforms.
 36. Themethod of claim 35, further comprising the steps of conveying a thirdweb of material spaced generally perpendicular from the first web and afourth web of material spaced generally perpendicular from the secondweb, each of the third and fourth webs being moved along web planemoving paths generally parallel with the first and second web planemoving paths, and wherein the applying step applies a section of elasticstrand onto the first, second, third and fourth webs along directionsgenerally transverse to said web moving direction.
 37. The system ofclaim 30, wherein the web conveyor assembly further includes a third webmoving platform for moving a third web thereon and a fourth web movingplatform for moving a fourth web thereon, wherein said third platform isspaced below said first platforms, said fourth platform is spaced belowsaid second platform, and said third platform is spaced laterally fromsaid fourth platform; and wherein said spinning head assembly ispositioned about said first, second, third, and fourth platforms to spinsaid section of elastic about said plane intersecting each of said websand applying elastic thereto.
 38. The system of claim 30, wherein saidplatforms are adapted for reciprocal motion such that the first orsecond web is initially moved in a first direction then moved in asecond direction opposite the first direction, each said web beingexposed to application of the section of elastic strand while moving inthe second direction.
 39. The system of claim 28, wherein each said webmoving platform includes a continuous movable belt.
 40. The system ofclaim 30, further comprising: a first source of the first web ofmaterial; a second source of the second web of material; and a foldingassembly operatively positioned between said sources of said first andsecond webs and said platforms, said folding assembly being adapted tofolding side edges of said webs to create folded flaps prior to the websbeing directed to the plane.
 41. The system of claim 30, furthercomprising: an input source of a third web of material; and a conveyingassembly for conveying said third web toward the first and second websafter said elastic strand is applied along the first and second webs,thereby creating a web substrate of a first and second web, a third web,and a plurality of elastic elements sandwiched therebetween.
 42. Thesystem of claim 41, further comprising a knife mechanism positioneddownstream of said plane and intermediate paths traveled by the firstand second webs to cut the section of elastic applied across the twowebs.
 43. The system of claim 42, further comprising a knife mechanismpositioned on laterally outside each of the paths of the first andsecond webs to cut the section of elastic applied across the two webs.44. The system of claim 42, wherein said conveying assembly is adaptedto convey a third web having a central fold along the center thereof,said system further comprising an unfolding mechanism positioneddownstream of the knife mechanism for unfolding the central fold toreveal a central non-elasticized region thereunder.
 45. The system ofclaim 30, wherein said spinning head assembly includes a drum having adispenser for dispensing the continuous elastic strand, said drum beinggenerally positioned about said web conveyor assembly to define a planetherethrough.
 46. A method of making an elastic composite forincorporation into a disposable absorbent garment, textile or fabricstructure, and the like, said method comprising the steps of: conveyinga first web of material along a first web plane moving path; conveying asecond web of material along a second web plane moving path generallyparallel with the first web plane moving direction; applying a sectionof a continuous strand of elastic element generally linearly onto boththe first web and the second web along a direction generally transverseto said web plane moving paths; and applying a matching web of materialonto the first and second webs after said applying step, therebyproviding a web of elastic composite comprising a single layer ofmatching web, laterally spaced layers of first and second webs, and aplurality of elastic strands sandwiched therebetween.
 47. The method ofclaim 46, further comprising the step of cutting the applied elasticstrand between the first and second webs, thereby providing a websubstrate having a pair of spaced apart longitudinally-extendingelasticized regions and a non-elasticized region therebetween.
 48. Themethod of claim 47, wherein the step of applying a matching web includesproviding a fold centrally along the single matching web, said methodfurther comprising the step of unfolding the central fold after saidcutting step to reveal a central non-elasticized region.
 49. The methodof claim 47, further comprising the steps of: moving the section ofelastic strand generally about a plane; wherein said conveying stepsincludes conveying the first and second webs of material along the webplane moving paths such that the first and second webs are spacedlaterally apart and intersect the plane, thereby applying the section ofelastic strand onto the first web and the second web.
 50. The method ofclaim 49, wherein the section of elastic strand is spun about the firstand second webs during the step of moving the section of continuousstrand.
 51. The method of claim 50, wherein the applying step includesapplying plurality of elastic elements in generally parallel relation onthe first and second webs.
 52. The method of claim 46, furthercomprising the step of cutting each applied section of elastic elementproximate each lateral side edge of the first and second web, therebyseparating each section from the continuous strand and leaving asegmented elastic element on the first and second webs.